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Digitalization in manufacturing

From assessment to successful implementation

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BMW Group Logo
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DERTOUR
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Dräger Logo
kuka
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Mercedes
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Das Logo der Bundesagentur für Arbeit
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Mercedes
Volkswagen Logo
DEKRA
stihl
Sonax_logo
Weidmüller logo
Das Logo der Bundesagentur für Arbeit
HomeServicesDigitalization of manufacturing

Successful digitalization in manufacturing with MaibornWolff

Do you want to digitize your manufacturing without technical ballast, but with tangible benefits? Then you've come to the right place. MaibornWolff brings IT and OT together to create manufacturing software that is not complicated, but clever: processes run leaner, data finally becomes useful and results are measurable.

Less technology. Better business.

Arrange a free consultation appointment

Why digitize manufacturing with MaibornWolff?

Architecture that grows with you

Scalable-by-design and open architecture keep your digitalization young. We decouple systems, standardize structures and reduce complexity - allowing new use cases to be created quickly and rolled out worldwide.

Data that speaks

With a unified namespace (MQTT), we clear up data silos: clean, structured, transparent and with clear responsibilities according to the data mesh principle. This means that machine data, ERP and MES finally speak the same language.

Integration that works

We integrate ERP, MES, SCADA/HMI and machine control systems pragmatically - without a tool circus, but with expertise in legacy, OPC UA and native protocols. The result: robust manufacturing software and peace of mind on the store floor.

Operation that stays

From assessment to operation, we supply the platform, applications and knowledge transfer from a single source. Security is not an appendage for us. Your teams become confident - and we stay on board as a partner when it comes to scaling.

Topics that will advance your business

Digitalization is transforming markets, processes, and business models—and presenting you with complex decisions. Our topic pages provide guidance: they show how we use strategy, technology, and experience to create solutions that have a lasting impact.

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Cloud

With the right cloud architecture, we combine technology and business value: automated, secure, scalable. This allows us to create space for innovation and sustainable competitiveness.

Topic Cloud
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Cybersecurity

Cybersecurity starts with clarity: We protect your systems, data, and processes with security by design—from risk analysis and penetration testing to DORA and NIS 2 compliance.

Topic Cybersecurity
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Data & AI

Aus Daten werden Entscheidungen, aus KI entsteht Wertschöpfung. Wir entwickeln datengetriebene Strategien, Modelle und Systeme, die Ihr Unternehmen messbar intelligenter machen.

Topic Data & AI
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Embedded Systems & Robotics

Intelligent systems start deep in the code. MaibornWolff develops robust embedded software and robotics solutions that perfectly combine precision, safety, and performance.

Topic Embedded
A highly automated factory in which a robotic arm with a digital interface operates in a futuristic environment.

Industry 4.0

Production processes are becoming smart, connected, and self-learning. We support you in the digital transformation of your factory—with IoT, cloud, edge, and AI for measurable efficiency.

Topic Industry 4.0
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IoT

Connected products create new business models. We combine hardware, software, and the cloud to create secure, scalable IoT solutions that make data usable and systems intelligent.

Topic IoT
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IT Consulting

Think strategically, implement operationally: MaibornWolff develops IT organizations, architectures, and processes that enable change and lead your business to sustainable success.

Topic IT Consulting
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IT modernization

Outdated systems slow down innovation. We modernize your IT during ongoing operations—with a clear strategy, clean code, and a focus on future viability and stability.

Topic IT Modernization
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Quality Engineering

Quality is not created at the end, but right from the start. We integrate testing, automation, and engineering to make software reliable, secure, and future-proof.

Topic Quality Engineering
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The employees save around six hours a week thanks to the new entry (iProcess).
Meik Hecker, Foreman Injection Molding Production, VW

Who is manufacturing software suitable for?

Manufacturing software is the lever for making digitalization tangible in production - from mechanical engineering to the food industry. It brings people, machines and data together, reduces tedious manual work and finally creates transparency across all plants.

For companies with an established system landscape, it provides a scalable bridge between ERP, MES, SCADA and the store floor. Traceability and GxP requirements are taken into account right from the start. We work for corporations and large SMEs that prefer to get things done rather than plan endlessly. Start quickly, learn, scale - with a focus on measurable benefits instead of buzzwords.

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Are you planning to digitize your manufacturing?

We provide an experienced end-to-end team of architects, OT/IT experts and developers. Together, we strengthen the status quo, prioritize use cases and deliver an MVP that runs productively in your environment - pragmatically, securely and scalably.

Book an appointment now!

Digitization of the industry: successfully mastering challenges

Whether automotive, mechanical engineering or the process industry: the biggest hurdle is rarely the technology. The challenge usually lies in the collaboration between IT and OT - or in the fact that data cannot be meaningfully linked and used. We structure the digitalization of production in such a way that it becomes viable and can be rolled out.

Which regularly throws a spanner in the works:

  • heterogeneous system landscapes

  • Legacy machines and protocols

  • Lack of internal know-how

  • Limited scalability

  • Long rollout times

  • Rigid processes

Our answer to this:

End-to-end services for production digitization - from analysis, architecture and implementation to operation:

  • Health checks to determine where you stand

  • Process and tool analysis for store floor apps

  • Concept development and architectural consulting for smart factories

  • Implementation of IIoT apps, integrations and operator UIs

  • Edge and cloud platforms, regardless of the cloud provider

  • Machine connection via OPC UA and native protocols

  • Test automation at all levels

  • Advice on scaling and maintainability

  • AR and mobile apps for industrial use

  • Secure remote access

Successful digitalization in the industry

To all references
  • A technician in a green Siemens jacket sits in front of a computer on a factory floor with industrial equipment in the background.
    Siemens: AI demand prediction platform for industrial production planning

    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.

    See Siemens reference
    Siemens: AI demand prediction platform for industrial production planning
    Project duration

    since February 2022

    Proof of concept

    in a few weeks

    Time series prediction

    for 100 different products

    See Siemens reference
  • VW drives through tunnel at night
    VW: Digitization of key production figures with the iProcess app

    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.

    See VW reference
    VW: Digitization of key production figures with the iProcess app
    Project duration

    since January 2021

    Team size

    5 to 10 persons

    Fast app development

    thanks to Digital Design

    See VW reference
  • Cars on assembly line in factory
    BMW Group: Replacement of a production-critical legacy system

    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.

    See BMW Group reference
    BMW Group: Replacement of a production-critical legacy system
    Project duration

    Mid-2018 to the beginning of 2024

    Team size

    25 employees

    Legacy system

    replaced after 20 years

    See BMW Group reference
  • Woman with tablet in modern factory hall
    KUKA: Web interface for a new Human Machine Interface

    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.

    See KUKA reference
    KUKA: Web interface for a new Human Machine Interface
    Goal

    Replacing the current control software

    iiQKA.OS

    Fast and intuitive development

    > 11,000 hours

    Project work

    See KUKA reference
  • Header_ifm
    ifm services: Remote maintenance of systems and machines

    Maintenance, anywhere and at any time - together with ifm services, we developed a remote access solution for industrial plants. A small, agile team created a full-stack cloud application that combines intuitive operation and secure connectivity. The product celebrated its premiere at HMI 2024.

    See ifm services reference
    ifm services: Remote maintenance of systems and machines
    Project duration

    since March 2023

    Remote Access

    integrated in platform

    Team

    5 Developers

    See ifm services reference
  • Control unit in an automated factory environment.
    Monitoring alarms in industrial plants

    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.

    See reference
    Monitoring alarms in industrial plants
    Project duration

    3 years

    <3 months

    to the MVP

    Cloud migration
    modernization & relocation
    See reference
  • Large rollers on conveyor belt in factory.
    Planning systems: Optimizing the capacity utilization of pressing plants

    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.

    See reference
    Planning systems: Optimizing the capacity utilization of pressing plants
    >10 years

    Customer support

    Technological modernization
    Cloud-ready platform
    Efficiency through data
    Site-specific cost planning
    See reference
  • Header_Global-Requirements-Planning-System-for-Workforce-2-16-9
    Global workforce planning system

    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.

    See reference
    Global workforce planning system
    Team size

    up to 8 employees

    Domain Driven Design

    development approach

    Microsoft Azure Cloud

    allows easy roll-out of new versions

    See reference
  • Man with tablet in front of KUKA industrial robots
    KUKA: UI/UX design for an app for load data analysis for industrial robots

    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.

    See KUKA reference
    KUKA: UI/UX design for an app for load data analysis for industrial robots
    Method

    Product Experience Design

    Customer request

    Easier interaction between users and the system

    Our goal
    Optimized load data analysis, fewer support requests, higher satisfaction
    See KUKA reference
  • A person stands in a modern, abstract room and holds a tablet in their hands.
    Weidmüller: Progression of the Industrial Service Platform

    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.

    See Weidmüller reference
    Weidmüller: Progression of the Industrial Service Platform
    Approx. 7 months

    up to the MVP

    8 weeks analysis

    of professional, technical and organizational factors

    Innovative portal

    for end-to-end solutions

    See Weidmüller reference

How does the digitalization of manufacturing work?

We start with a clear vision and a look at the current situation. Then we select the use cases that really make a difference - not the ones that just sound good. A productive MVP delivers initial results, after which we roll it out across all plants and get your teams ready for scaling.

End-to-end services: from analysis to operation

With over ten years of IIoT and smart factory experience in more than 30 projects, we combine software development, OT expertise and architecture know-how. From consulting to infrastructure to operation: we deliver everything from a single source - with governance and security by design, of course. Or as we would say: Not a piecemeal approach, but a system with understanding.

Would you like to become a satisfied MaibornWolff customer yourself?

Contact us now

Frequently asked questions about digitalization in manufacturing

The regulatory requirements for energy companies are subject to constant change. Here you will find answers to the most important questions on current legal requirements, political developments and their impact on the digitalization of the energy industry (as of 03/2025).

  • What trends are currently driving the digitalization of manufacturing?

    In short: paperless production, connected worker apps and a clean database. Unified namespace (UNS) is becoming the standard for breaking down data silos. At the same time, the infrastructure level is gaining in importance: those who standardize their platforms can roll out new use cases faster - without having to reinvent every plant.

  • Why is a standardized infrastructure so crucial?

    Many digital projects fail due to rollout and technology. A shared, standardized infrastructure saves effort, reduces operating costs and makes scaling possible - especially for companies with multiple plants. Kubernetes & Co. help to automate deployments and maintenance. The result: less complexity, more speed.

  • What audit and compliance requirements apply in manufacturing?

    GxP requirements are mandatory in highly regulated industries such as pharmaceuticals: data must remain tamper-proof and traceable. Traceability (track & trace) is also becoming more important across all industries. Paying attention to data integrity right from the architecture stage saves you stress with audits later on - and lets you sleep more soundly.

  • How does MaibornWolff approach IT/OT security?

    Security is considered right from the start of every project. Communication above the PLC level is encrypted, workloads are operated on-prem or in the cloud as required. It is important that those responsible for security are involved at an early stage - this ensures that protection remains effective without slowing down innovation.

Guide on the topic of "Digitalization in manufacturing"

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    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.

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