
Building a smart factory platform using Azure IoT Operations
From a solution assessment to a productive Minimum Viable Product (MVP)
Streamline Production with Azure IoT Operations
Modern factories produce vast amounts of data. But, bringing that data to good use, to optimize planning, streamline production and gain deeper insights into processes to optimize them, remains a challenge. We explain how data operations tools like Azure IoT Operations can help to transform raw production data into valuable information for manufacturing companies.
Transforming raw data into information
Modern manufacturing sites with oftentimes complex automated production processes produce terrabytes of data, sometimes daily. Just storing the raw data in a database or a datalake and trying to extract insights out of it is time consuming, causes a lot of effort and is a potential roadblock for fast realization of digital use cases.
The problem with raw process data is, that it is not normalized or standardized and often lacks context. Although a single process value can be used for simple monitoring, deeper insights can only be gained if process values can be correlated with other data and information like machine failures, environmental data or order information.
Normalization helps, when it comes to analyzing the data: Naming conventions, standardized units and timestamps allow data scientists to do their work more efficiently. They might not have a direct connection to the process. Therefore, they need additional context such as the units of measurement of the datapoints and a clear assignment to the data sources.
The following steps show, how connectivity solutions can help to improve data quality to enable data driven use cases:
With machine connectivity solutions that provide means to transform and normalize data like Azure IoT Operations, we can abstract from the differences between the plants and machine manufacturers and reduce the effort required to roll out use cases to other plants.
Efficient data processing and networking
Getting access to the raw data is the first step. Connectivity solutions support machine protocols to directly connect to the machines, e.g. via OPC-UA.
In the transformation and normalization step, raw data can be transformed to common units of measurement and defined data types.
The use of standard data models helps to abstract from the differences between machines from different generations or different manufacturers. This step is crucial to harmonize data from different sites and to allow for scalability of faster roll-out.
By publishing normalized and standardized data to a UNS, this data gets additional context from the topic hierarchy. It is easily accessible for other interested clients and systems in a company and allows for faster problem solving and use case realization.

MaibornWolff has been instrumental in shaping our product journey. Their commitment to sharing deep technical, industrial knowledge and providing invaluable feedback through testing has been pivotal in shaping Azure IoT Operations.
Building a data plane with Azure IoT Operations

Machine connectivity
We leverage machine connectivity tools that can connect directly to machines and processes and provide data transformation and normalization as close to the data source as possible. The use of standardized data models to harmonize data for example across similar machines from different manufacturers is another feature.
Standardized data level
Azure IoT Operations is a unified data plane for the edge. It’s a collection of modular, scalable, and highly available data services. It enables data capture from various systems: It allows for example to connect to machines via OPC-UA, transform and normalize the data close the edge and publish it via industry standards like MQTT. Using 3rd Party solutions it can be extended to support additional industrial protocols beyond OPC UA.
UNS based architecture
Besides this “DataOps” functionality Azure IoT Operations also includes the highly available and scalable MQTT broker Azure IoT MQ which can be used to build a Unified Namespace based architecture. With these capabilities Azure IoT Operations makes it possible to publish normalized data from the edge to a Unified Namespace running inside Azure IoT MQ. This potentially makes data accessible to all other interested clients and systems in the company.
Collaboration with Microsoft

We have worked closely together with Microsoft during the development of Azure IoT Operations and continue to do so. From our work with manufacturing clients, we know what they want and need to make better use of their production data. We shared our learning with the Microsoft product group at an early stage and provided constant feedback during the development and private preview phases. Due to this collaboration, we already possess deep knowledge about Azure IoT Operations.

Key features of Azure IoT Operations
It Includes an industrial-grade, highly available and scalable MQTT broker that powers event-driven architectures and can form the foundation for a Unified Namespace.
It is highly extensible, scalable, resilient, and secure.
It lets you manage edge services and resources from the cloud by using Azure Arc.
It can integrate customer workloads into the platform to create a unified solution.
It supports a GitOps- and IoC-based approach for deployment and configuration.
It natively integrates with Azure Event Hubs, Azure Event Grid’s MQTT broker, and Microsoft Fabric in the cloud.
Building a Smart Factory is more than connecting machines
When working together with our customers on their Smart Factories, a fit gap analysis is always part of our approach. We take a close look at the existing application landscape and examine if tools like Azure IoT Operations can fill the gaps or if additional components are necessary for example to connect to legacy devices, that do not provide their data via OPC-UA.
Even though quality data is the basis for actionable insights, building a Smart Factory is more than connecting machines, and providing access to data. Besides the data layer the infrastructure is key success factor for digital transformation and has significant influx on the operability, scalability and security of the Smart Factory.
When a company is starting to plan their digital infrastructure, several requirements and constraints influence what an overall Smart Factory platform based on tools like Azure IoT Operations should look like:
On the one side there are requirements that are often specific to each company. These requirements include aspects like use cases and workloads or industrial protocols that need to be supported. Another aspect is whether multiple development teams will work on the platform.
On the other side there also a specific constraints and requirement from infrastructure, security and networking perspective. Examples would be topics like network segmentation, existing digital infrastructure or security guidelines that need to be considered.
No more PoCs.
Instead build a MVP.
Building a smart factory is as much about people as it is about technology. Even the most flexible and scalable infrastructure will be useless, when the people are missing that define and build use cases that crate actual value for the users and the company. When we work together with manufacturing clients on their Smart Factories, we follow a 4 step approach that reflects this and brings together people and technology:
In the Solution Assessment we…
- educatate on the success factory and core concepts for a Smart Factory
- create guide our customers to define an aligned product vision & roadmap
- define Core capabilities and constraints
- create a high level overview of potential use cases and specify an initial use case for the MVP pahse
- make a fit gap analysis and define the tools set, that are best suitable for our clients
- define the Smart Factory architecture & tech stack
- define the MVP scope
- prepare the implementation phase
We build a Minimum Viable Product:
- We build the initial infrastructure tailored to the customer
- We build an initial use case in one plant
- We take care of operational readiness and the initial go-live
- We collect early user feedback
Iteration & Progressive Handover
- Add features & use cases
- Rollout into more plants
- Ramp-up of a development team on the customer side
- We transfer our know-how to enable the customers to take over operations
Our references & projects
A reference is worth more than 1,000 words. Fortunately, we have dozens of them. Click through a selection of our most exciting projects and see for yourself!
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MAN: Efficient threat analysis for control unitsSee MAN reference
Digitalization increases cyber risks - especially for MAN's new CM4 control unit. Our experts use the 4×6 methodology and ThreatSea to identify threats at an early stage and develop targeted protective measures. Find out how MAN uses intelligent risk analysis to strengthen the security of its vehicles.
MAN: Efficient threat analysis for control unitsSee MAN reference7 monthsProject duration
Over 20 workshopsThreat analyses
Over 500Potential risks evaluated
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Siemens: AI demand prediction platform for industrial production planningSee Siemens reference
Siemens is looking to the future with the AI Demand Prediction Platform. Thanks to machine learning and AutoML, precise demand forecasts can be created for over 100 products and production can be better planned. Launched as a proof of concept, the platform quickly developed into a system that can be used productively. The self-service web application will soon be used in other plants.
Siemens: AI demand prediction platform for industrial production planningSee Siemens referenceProject durationSince February 2022
Proof of conceptin a few weeks
Time series predictionfor 100 different products
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TÜV NORD GPT: Development of AI assistanceSee TÜV NORD reference
Find relevant information faster by chatting with documents? It's possible! The TÜV NORD GROUP uses GPT technology in the secure Microsoft Azure Cloud. With the aim of optimizing knowledge management and efficiency. The system enables new usage options within the testing group and is operated securely. Find out more about the innovative AI assistance system now.
TÜV NORD GPT: Development of AI assistanceSee TÜV NORD referenceProject durationsince September 2023
33.000GPT applications in the first month
ChatGPT Model 4in the European Microsoft Azure Cloud
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Schöck components: Improvement of the requirements processSee Schöck Bauteile reference
Together with MaibornWolff, the construction industry specialist optimized the requirements management of its Scalix design software. Thanks to the digital design approach, the technical requirements were re-specified and the software was further developed in a user-centered manner. The aim is to continuously increase user satisfaction and integrate internal and external interests. Read more about the methodology and results now!
Schöck components: Improvement of the requirements processSee Schöck Bauteile referenceProject durationsince 2022
Team size2-3 Digital Designer:inside
In 2024Scalix replaces old software -
VW: Digitization of key production figures with the iProcess appSee VW reference
Less paper, more efficiency: Volkswagen replaces analog processes with the iProcess app. Cloud-native technologies and digital design enable intuitive recording and analysis of key production figures. This increases transparency and overall equipment effectiveness and paves the way for predictive maintenance at the automotive group.
VW: Digitization of key production figures with the iProcess appSee VW referenceProject durationSince January 2021
Team size5 to 10 persons
Fast app developmentthanks to Digital Design
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DER Touristik: Become a digital travel companion in 7 monthsSee DER Touristik reference
Travel information, bookings, support - all in one app. With Flutter, MaibornWolff developed a cross-platform solution for DER Touristik. In just seven months, a stable app was created for iOS and Android that supports multiple brands, languages and countries. This is how customer proximity travels.
DER Touristik: Become a digital travel companion in 7 monthsSee DER Touristik reference7 monthsFrom Kickoff to Go Live
iOS and AndroidDigital travel companion
Whitelabelling solutionUncomplicated integration of additional brands, languages and countries
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Mixed reality: driving a real car in a virtual worldSee BMW reference
Virtual racing in a real car? MaibornWolff made it possible for the BMW M. Within three months, we used Unreal Engine 4 to develop a prototype that processes vehicle signals with high performance and creates an immersive driving experience without motion sickness. The cockpit remains real, the surroundings become the racetrack.
Mixed reality: driving a real car in a virtual worldSee BMW reference<3 monthsFrom the vision to the prototype
3D applicationsin real time
TeamUnreal development, XR technology, game design, smart devices, 3D content
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KUKA: Web interface for a new Human Machine InterfaceSee KUKA reference
Rethinking robotics: KUKA is working with us to develop iiQKA.OS - an operating system with an intuitive web HMI. Using web technologies and scrum methods, we enable flexible customization and simple control. Open collaboration makes robotics more accessible than ever before.
KUKA: Web interface for a new Human Machine InterfaceSee KUKA referenceGoalReplacing the current control software
iiQKA.OSFast and intuitive development
> 11,000 hoursProject work
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STIHL: Control iMOW robotic mower via appRead more
Robot mower redefined: The iMOW from STIHL makes lawn care smarter. Our software expertise combined with STIHL's hardware know-how ensures intuitive app control. The result? A networked device that makes gardening easier - simple, efficient, innovative.
STIHL: Control iMOW robotic mower via appRead moreProject durationsince August 2020
Robot mowerControl via app
Process optimizationwith the customer
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DEKRA: Modern enterprise architecture thanks to co-creationSee DEKRA reference
New IT for a sustainable future: the global auditing group needed to modernize its IT landscape. Co-Creation created a harmonized architecture and the EA Community promotes cross-border exchange for strong IT until 2025 - and beyond.
DEKRA: Modern enterprise architecture thanks to co-creationSee DEKRA referenceMost important method:Building an EA community
Created conceptEnterprise Architecture
Cooperationat eye level
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Miele domestic appliances are networked worldwideSee Miele reference
How do household appliances become smart? Miele relies on an IoT platform that we played a key role in developing. Container-based architecture ensures stable communication, DevOps for continuous improvement - so that smart appliances can be found in millions of households worldwide.
Miele domestic appliances are networked worldwideSee Miele referenceProject durationsince 2016
Success factors:High availability and scalability
IoT platformwith container-based architecture
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MAN: Secure Software Development Life CycleSee MAN reference
Trucks are networked - and therefore unfortunately also targets for attack. With SSDLC, MAN relies on security by design and integrates the highest security standards directly into development. Together with 22 teams, we have established security measures that go beyond the legal requirements.
MAN: Secure Software Development Life CycleSee MAN reference22 monthsProject duration
UNECE R155successfully integratedMethodsSecurity Champions, DevSecOps, OWASP SAMM
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It's LOS: Building a cloud-based low-code applicationSee Es geht LOS reference
Democracy meets digitalization: For "Es geht LOS!", we developed a low-code app for candidate management in five weeks. Built on AWS, it enables secure draws and efficient user management - for more citizen participation digitally.
It's LOS: Building a cloud-based low-code applicationSee Es geht LOS referenceProject durationSince the beginning of 2022
MVPin only 5 weeks
TechnologiesAmplify, AppSync, CodeCommit, IAM, Cognito, DynamoDB, Lambda
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Monitoring alarms in industrial plantsSee reference
Safety in industrial plants requires a real-time overview. We developed a live monitoring platform that networks measuring devices and collects data via Azure IoT and Kubernetes. A scalable MVP was created in just three months: alarms appear in under ten seconds thanks to automated data acquisition via smartphone and Bluetooth.
Monitoring alarms in industrial plantsSee reference3 yearsProject duration
<3 monthsto the MVP
Cloud migrationModernization & relocation -
Planning systems: Optimizing the capacity utilization of pressing plantsSee reference
Maximum capacity utilization, minimum costs: Our customer relies on a central planning system for pressing plants. We have been supporting its further development with .NET Core, GraphQL and PostgreSQL for over ten years. Now the journey is moving to the cloud - for greater scalability, flexibility and efficiency.
Planning systems: Optimizing the capacity utilization of pressing plantsSee reference>10 yearsCustomer support
Technological modernizationCloud-ready platformEfficiency through dataSite-specific cost planning -
Global workforce planning systemSee reference
How do you achieve globally harmonized workforce planning? With a modern web application based on domain-driven design and hexagonal architecture. Event sourcing ensures transparent traceability, while Azure and Quarkus provide stability and scalability. The result: a flexible, future-proof solution.
Global workforce planning systemSee referenceTeam sizeUp to 8 employees
Domain Driven DesignDevelopment approach
Microsoft Azure Cloudallows easy roll-out of new versions
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DER Touristik Online: Development and migration of a multi-client capable travel booking platformSee DER Touristik reference
Different brands, one platform: DER Touristik merges several independent websites. We are supporting the migration to the AWS cloud with digital design, microservices and testing. The focus is on performance, SEO and UX - for a seamless digital travel experience.
DER Touristik Online: Development and migration of a multi-client capable travel booking platformSee DER Touristik referenceStandardized platformMulti-client travel portalQuality assuranceEnd-2-End test automationCloud transformationMigration to AWS cloud -
KUKA: UI/UX design for an app for load data analysis for industrial robotsSee KUKA reference
How do you reduce support requests? With a smart UX! KUKA and MaibornWolff developed a web-based application for load data analysis. Through "Understand/Build/Learn" we recognized challenges early on and validated solutions for an intuitive user experience.
KUKA: UI/UX design for an app for load data analysis for industrial robotsSee KUKA referenceMethodProduct Experience Design
Customer requestEasier interaction between users and the system
Our goalOptimized load data analysis, fewer support requests, higher satisfaction -
BMW Group: Replacement of a production-critical legacy systemSee BMW Group reference
20-year-old system, new digital future. We gradually migrated production software to a flexible architecture. After two years, central plants were running on the new solution - stable, fail-safe and ready for the challenges of tomorrow.
BMW Group: Replacement of a production-critical legacy systemSee BMW Group referenceProject durationMid-2018 to the beginning of 2024
Team size25 employees
Legacy systemreplaced after 20 years
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BMW Group: Virtual reality brings vehicle design to lifeSee BMW Group reference
From the first draft to series production - BMW uses VR to visualize the entire development process. Based on the Unreal Engine, a uniform platform visualizes designs and processes. This saves on hardware prototypes and enables location-independent collaboration. MaibornWolff plays a key role in driving the development and integration of these VR use cases.
BMW Group: Virtual reality brings vehicle design to lifeSee BMW Group reference3.2 yearsProject duration
CooperationLocation-independent and virtual
InfrastructureScalable and expandable thanks to the cloud
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BMW Group: Remote software upgrade for vehiclesSee BMW Group reference
No visits to the workshop, no stress - thanks to Remote Software Upgrade, BMW vehicles worldwide remain up-to-date "over-the-air". MaibornWolff has been developing and operating the backend for secure updates for over three years. Microservice architectures and DevOps approaches guarantee stability, performance and security.
BMW Group: Remote software upgrade for vehiclesSee BMW Group reference5 yearsProject duration
Millions of vehiclesreceive new features thanks to "over-the-air" upgrade
IT securityAlways up-to-date thanks to remote software upgrade
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Creditreform: Secure proof of identity on the webSee Creditreform reference
Verifying online identities in a forgery-proof manner while maintaining user-friendliness - CrefoTrust makes it possible. Together, we developed a solution that creates trust with blockchain technology and proofs of concept. Personal and company data remain protected, while verifications run smoothly.
Creditreform: Secure proof of identity on the webSee Creditreform reference5 yearsProject duration
Pilot testsbased on several PoCs
Decentralized identityallows tamper-proof storage of identities and company information
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Bayernwerk: Knowledge management via teamsRead more
Experience must not be lost - Bayernwerk digitizes the knowledge of long-standing employees. MaibornWolff designed an intuitive MS Teams app with a clear UX/UI. Close collaboration, lived Scrum values and user-centered development make the app a success. Promoting exchange, optimizing processes - this is how knowledge transfer works today.
Bayernwerk: Knowledge management via teamsRead more6 monthsProject duration
Target:Identify implicit knowledge
Requirements:a user-centered, intuitive and clear UX/UI design
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Weidmüller: Progression of the Industrial Service PlatformRead more
IoT meets agility - Weidmüller and MaibornWolff developed the easyConnect platform for remote access, data visualization and machine learning. After intensive exploration, an MVP was created, accompanied by a cross-functional Scrum team. Making Industrial IoT smarter and more efficient.
Weidmüller: Progression of the Industrial Service PlatformRead more12 monthsup to the MVP
8 weeks analysisof professional, technical and organizational factors
Innovative portalfor end-to-end solutions
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SMA: Development of a Web UI for ennexOS platformSee SMA reference
Optimizing energy flows, reducing costs - we have been developing the Web UI of the ennexOS platform with SMA Solar Technology since 2016. It digitizes energy management processes for over a million users and combines smart solutions for a sustainable energy future.
SMA: Development of a Web UI for ennexOS platformSee SMA referenceProject durationsince 2016
> 1.000Modules and components in ennexOS platform
> 7.000Fuse tests
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digikoo GmbH: Apple Vision Pro for city plannersSee digikoo reference
Planning cities smarter: Together with TUM, we developed the 3Digipad for Apple Vision Pro. It visualizes complex energy data in 3D and makes scenarios intuitively tangible. Dynamic building data and KPIs support urban planners in making sustainable decisions.
digikoo GmbH: Apple Vision Pro for city plannersSee digikoo reference4 monthsProject duration
3D map with KPIsDisplay building data dynamicallyEnergy dataImmersive visualization -
digikoo: A data platform for the Azure CloudSee digikoo reference
Structured geodata, automated quality assurance, seamless provision - we developed a powerful Snowflake data platform on Azure for Digikoo. It makes analysis easier for data scientists and lays the foundation for precise forecasts and new use cases.
digikoo: A data platform for the Azure CloudSee digikoo reference5 monthsProject duration
Climate changePlan digitally and implement efficiently
Foundation data platformMicrosoft Azure Cloud
Why MaibornWolff?
As one of the most innovative IT service providers with a great passion for AI, we focus entirely on the project business and individual software development - without our own products. To stay at the forefront, we continuously invest in our team of digital technology engineers and develop digital solutions that are well thought-out, efficient and reduced to the essentials.
Our principle: simplicity instead of complexity. We only develop what is really needed - tailor-made, useful and reliable. Our results speak for themselves. With over 800 large-scale systems and more than 10,000 person-years of experience in high-end software engineering, we are one of the few who can reliably implement even the largest and most complex IT landscapes. Thanks to close partnerships with leading hyperscalers, our customers operate their solutions in today's most modern and powerful environments.
Less technology. Better Business.