Smart Industry Consulting: Intelligently connecting production, managing it with data, and scaling it resiliently

Digital Transformation Strategy for Manufacturing Companies
Prioritizing digital initiatives with a robust business case, tailored to production realities, the system landscape, and organizational maturity. This ensures that management and operations know which investments deliver the greatest value and in what order they should be implemented.

Smart Factory Target Model & Architecture Vision
Defining a Consistent Target Architecture for Your Smart Factory: What systems, data flows, levels of automation, and governance mechanisms are necessary to ensure that individual initiatives do not become siloed solutions, but rather contribute to a scalable overall picture?

Technology Scouting & Innovation Roadmap
Systematic evaluation of new technologies based on operational feasibility, regulatory maturity, and economic potential. Structured integration into the production strategy.

Smart Industry Governance & Management
Establishing clear decision-making structures, prioritization mechanisms, and review processes for managing all smart industry initiatives, so that the transformation does not fizzle out in a project-by-project approach but is instead carried out as a coherent program.

AI Strategy for Production
Identification, evaluation, and prioritization of AI use cases with a real impact on production: quality prediction, process optimization, demand forecasting, anomaly detection, and autonomous control. No AI hype—just robust business cases with realistic ROI.

AI-Powered Manufacturing Assistance
When AI systems support your employees in making quality decisions and controlling processes in real time, consistency improves without replacing experiential knowledge. Better decisions, more consistent quality, and less strain at critical points.

Predictive Maintenance & Condition Monitoring
Unplanned downtime doesn’t just cost time—it erodes customer trust and reduces flexibility in the supply chain. AI-powered predictive maintenance detects wear and anomalies early enough to allow your maintenance teams to act proactively rather than reactively.

Human-AI Teaming & Workforce Enablement
Technology only realizes its full potential when people embrace and master it. We design the interaction between humans and machines in a way that empowers—rather than replaces—skilled workers: with clearly defined roles, assistance systems integrated into work processes, and structured skills development.

Cobots, Robotics & Autonomous Manufacturing
Cobots take over physically demanding, monotonous, or error-prone tasks directly on the job floor, while your employees focus on tasks that require experience and judgment. Gradually increase autonomy all the way to self-directed manufacturing.

IT/OT Architecture & Target Vision
Harmonization of legacy ERP, MES, SCADA, and WMS systems into an integrated production architecture. Capability-based target architectures bridge global requirements and local plant needs, establishing end-to-end data flows along the entire IT/OT continuum.

Data & Integration Architecture
: Modeling end-to-end data flows between production and enterprise systems. Defining lead systems for each data object and establishing standardized interfaces. Consistent master data and end-to-end process logic across all levels create a reliable basis for real-time decision-making.

Data Strategy & Smart Manufacturing Analytics
Making production data systematically usable: from real-time dashboards to process mining to AI-powered quality forecasting. So that manufacturing decisions are based on data rather than gut feelings.

Architecture Governance & Scaling
Clear roles, documented architecture decisions (ADR), and cross-plant review processes ensure that decisions remain transparent and consistent. Standardized capability models enable faster rollouts across plants, regions, and business units.

OT Security & Cyber Resilience
Networked production environments are both more efficient and more vulnerable. NIS2 makes OT protection a legal requirement. We integrate cybersecurity as an integral part of your production architecture: network segmentation, access control, anomaly detection, and resilient system architectures with clear separation and redundancies.

Cybersecurity Assessment & Compliance
Assessment of your OT security posture in accordance with IEC 62443, NIS2, the KRITIS Regulation, and industry-specific requirements. Identification of critical risks, prioritization of measures, and establishment of demonstrable compliance.

Functional Safety for Intelligent Systems
The more autonomous production systems become, the higher the requirements for functional safety. We integrate safety concepts in accordance with IEC 61508/62443 and the Machinery Directive into the system design process: hazard analysis, risk assessment, safety architecture, and verification as an integral part of system development.

Security-by-Design in Production Architecture
Cybersecurity and functional safety are not added as an afterthought, but are integrated from the very beginning into architectural decisions, system design, and operational processes. This ensures that security becomes an enabler rather than an obstacle to digitalization.

Digital Twin: Product, Manufacturing & Operations
Digital twins that are maintained throughout the entire lifecycle: from the development twin to the manufacturing twin to the operational twin, which consolidates real-time operational data, status information, and maintenance histories.

Production Simulation & Factory Planning
New line concepts, levels of automation, or cycle times can be simulated virtually before any investment is made. This reduces start-up risks, shortens implementation times, and transforms investment decisions—which are difficult to calculate—into scenarios that can be reliably evaluated.

Digital Engineering & Product Development
Slow development costs market share; unclear requirements cost budget. We support the process from requirements definition through model-based methods (MBSE) to production-ready implementation, so that complexity becomes manageable and innovation reaches production faster.

Requirements Engineering 2.0
: Capture requirements with high precision and manage them consistently from the market all the way through to production. For higher product quality, less rework, faster approvals, and a shared understanding across all departments.

Sustainable Manufacturing & ESG Compliance
ESG reporting requirements, CBAM, and the Digital Product Passport are creating significant pressure. Those who treat sustainability as a mere compliance issue bear the costs without reaping the benefits. We strategically integrate sustainable production processes: as a lever for energy and material efficiency and as a foundation for new market opportunities.

Circular Economy & Resource Efficiency
Circular economy approaches to reducing raw material use and lowering costs. From material selection and manufacturing process optimization to returning materials to the production cycle.

Organizational Development for the Smart Factory
Defining role models, responsibilities, and collaboration formats that establish production, IT, OT, and development as an integrated system. New roles such as data engineers, automation specialists, and digital manufacturing managers are assigned clear tasks and decision-making authority.

Change Management for Manufacturing Companies
Manufacturing companies are often steeped in tradition and have a strong shop-floor culture. Change requires a special level of sensitivity. We design change processes that engage foremen, technicians, and engineers and embed digital workflows in a sustainable way.

AR/VR Assistance Systems for Knowledge Transfer
Complex assembly steps, rare special cases, quickly training new employees: Augmented Reality delivers the necessary support directly into the user’s field of view. Error rates drop, training times are shortened, and knowledge remains within the system rather than just in individual minds.