A digital visualization of a futuristic industrial plant symbolizes the concepts of Industry 4.0 consulting.

Industry 4.0 consulting

How the transformation in production succeeds
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HomeServicesIndustry 4.0Industry 4.0 Consulting

Efficiency redefined: Industry 4.0 consulting

Reduce machine downtime by 30 to 50 percent, increase labor productivity by 15 to 30 percent and make forecasts, such as those of demand and production requirements, 85 percent more accurate? (McKinsey, 2022) Sound utopian? Industry 4.0 technologies make exactly that possible!

In our Industry 4.0 consulting service, we show you how you can integrate smart digital technologies into your company's production processes in order to position yourself for the future.

Holistic approach

We accompany you from the initial idea through the conception to the complete implementation and operation of the solution.

Success through knowledge transfer

We work with you to develop and implement Industry 4.0 solutions and help you to build up knowledge in your company. In this way, we enable you to implement projects independently in the future.

Integration of existing systems

We ensure that new solutions communicate seamlessly with your existing systems and platforms.

Return on investment

We work with you to define measurable Industry 4.0 use cases and support you in estimating the ROI for your budget planning.

Expert knowledge

With almost 1,000 experts in interdisciplinary teams - from data engineers to IoT, cloud and smart factory specialists - we have all the skills in-house to flexibly scale your projects.

Three people are in a meeting, working on a laptop, discussing Industry 4.0 consulting.
Are you ready to take your production to the next level?

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!

  • A red MAN truck drives along an empty road under a clear night sky with shining stars.
    MAN: Efficient threat analysis for control units

    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.

    Learn more
    MAN: Efficient threat analysis for control units
    7 months

    Project duration

    Over 20 workshops

    Threat analyses

    Over 500

    Potential risks evaluated

    Learn more
  • 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.

    Read more
    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

    Read more
  • Two women are standing in a workshop. One woman is holding a tablet in her hands.
    TÜV NORD GPT: Development of AI assistance

    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.

    Read more
    TÜV NORD GPT: Development of AI assistance
    Project duration

    since September 2023

    33.000

    GPT applications in the first month

    ChatGPT Model 4

    in the European Microsoft Azure Cloud

    Read more
  • Carousel_Schöck_Components-1
    Schöck components: Improvement of the requirements process

    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!

    Read more
    Schöck components: Improvement of the requirements process
    Project duration

    since 2022

    Team size

    2-3 Digital Designer:inside

    In 2024
    Scalix replaces old software
    Read more
  • 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.

    Read more
    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

    Read more
  • Woman on the beach at sunset with laptop.
    DER Touristik: Become a digital travel companion in 7 months

    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.

    Read more
    DER Touristik: Become a digital travel companion in 7 months
    7 months

    From Kickoff to Go Live

    iOS and Android

    Digital travel companion

    Whitelabelling solution

    Uncomplicated integration of additional brands, languages and countries

    Read more
  • Sports car parked in a colorful desert landscape.
    Mixed reality: driving a real car in a virtual world

    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.

    Read more
    Mixed reality: driving a real car in a virtual world
    <3 months

    From the vision to the prototype

    3D applications

    in real time

    Team

    Unreal development, XR technology, game design, smart devices, 3D content

    Read more
  • 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.

    Read more
    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

    Read more
  • Header_Stiehl-IMOW-16-9
    STIHL: Control iMOW robotic mower via app

    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.

    Read more
    STIHL: Control iMOW robotic mower via app
    Project duration

    since August 2020

    Robot mower

    Control via app

    Process optimization

    with the customer

    Read more
  • Woman smiling while driving into vehicle.
    DEKRA: Modern enterprise architecture thanks to co-creation

    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.

    Read more
    DEKRA: Modern enterprise architecture thanks to co-creation
    Most important method:

    Building an EA community

    Created concept

    Enterprise Architecture

    Cooperation

    at eye level

    Read more
  • Person uses Miele app in modern kitchen.
    Miele domestic appliances are networked worldwide

    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.

    Read more
    Miele domestic appliances are networked worldwide
    Project duration

    since 2016

    Success factors:

    High availability and scalability

    IoT platform

    with container-based architecture

    Read more
  • Man checks MAN trucks at sunset.
    MAN: Secure Software Development Life Cycle

    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.

    Read more
    MAN: Secure Software Development Life Cycle
    22 months

    Project duration

    UNECE R155
    successfully integrated
    Methods

    Security Champions, DevSecOps, OWASP SAMM

    Read more
  • Header_It_goes_LOS
    It's LOS: Building a cloud-based low-code application

    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.

    Read more
    It's LOS: Building a cloud-based low-code application
    Project duration

    Since the beginning of 2022

    MVP

    in only 5 weeks

    Technologies

    Amplify, AppSync, CodeCommit, IAM, Cognito, DynamoDB, Lambda

    Read more
  • 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.

    Read more
    Monitoring alarms in industrial plants
    3 years

    Project duration

    <3 months

    to the MVP

    Cloud migration
    Modernization & relocation
    Read more
  • 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.

    Read more
    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
    Read more
  • 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.

    Read more
    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

    Read more
  • Couple walking on the beach at sunset.
    DER Touristik Online: Development and migration of a multi-client capable travel booking platform

    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.

    Read more
    DER Touristik Online: Development and migration of a multi-client capable travel booking platform
    Standardized platform
    Multi-client travel portal
    Quality assurance
    End-2-End test automation
    Cloud transformation
    Migration to AWS cloud
    Read more
  • 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.

    Read more
    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
    Read more
  • 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.

    Read more
    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

    Read more
  • A person wearing virtual reality glasses drives a car in an urban environment at night with illuminated buildings in the background.
    BMW Group: Virtual reality brings vehicle design to life

    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.

    Read more
    BMW Group: Virtual reality brings vehicle design to life
    3.2 years

    Project duration

    Cooperation

    Location-independent and virtual

    Infrastructure

    Scalable and expandable thanks to the cloud

    Read more
  • The dashboard of a car shows a display with a notification about a remote software upgrade.
    BMW Group: Remote software upgrade for vehicles

    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.

    Read more
    BMW Group: Remote software upgrade for vehicles
    5 years

    Project duration

    Millions of vehicles

    receive new features thanks to "over-the-air" upgrade

    IT security

    Always up-to-date thanks to remote software upgrade

    Read more
  • A person in a modern office checks proof of identity on the web on a laptop and smartphone.
    Creditreform: Secure proof of identity on the web

    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.

    Read more
    Creditreform: Secure proof of identity on the web
    5 years

    Project duration

    Pilot tests

    based on several PoCs

    Decentralized identity

    allows tamper-proof storage of identities and company information

    Read more
  • High-voltage power lines over a green field at sunset
    Bayernwerk: Knowledge management via teams

    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.

    Read more
    Bayernwerk: Knowledge management via teams
    6 months

    Project duration

    Target:

    Identify implicit knowledge

    Requirements:

    a user-centered, intuitive and clear UX/UI design

    Read more
  • 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.

    Read more
    Weidmüller: Progression of the Industrial Service Platform
    12 months

    up to the MVP

    8 weeks analysis

    of professional, technical and organizational factors

    Innovative portal

    for end-to-end solutions

    Read more
  • Technician installs solar panel on roof at sunset
    SMA: Development of a Web UI for ennexOS platform

    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.

    Read more
    SMA: Development of a Web UI for ennexOS platform
    Project duration

    since 2016

    > 1.000

    Modules and components in ennexOS platform

    > 7.000

    Fuse tests

    Read more
  • Digikoo_Apple_vision_Pro_Header
    digikoo GmbH: Apple Vision Pro for city planners

    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.

    Read more
    digikoo GmbH: Apple Vision Pro for city planners
    4 months

    Project duration

    3D map with KPIs
    Display building data dynamically
    Energy data
    Immersive visualization
    Read more
  • Server room with green planting, demonstrating data platform for the Azure Cloud.
    digikoo: A data platform for the Azure Cloud

    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.

    Read more
    digikoo: A data platform for the Azure Cloud
    5 months

    Project duration

    Climate change

    Plan digitally and implement efficiently

    Foundation data platform

    Microsoft Azure Cloud

    Read more

MaibornWolff Industry 4.0 consulting: your benefits

The motivation for digital transformation in production with the help of Industry 4.0 consulting can be easily summarized: it ensures the long-term competitiveness of companies. This is achieved by optimizing the following areas, among others, in which we have already been able to achieve tangible and measurable success for our clients:

Costs

Produce faster and more cost-effectively.

Environment

Save energy and material.

Quality

Detect errors faster and improve quality.

Working conditions

Improve working conditions and reduce manual activities.

Product

Optimize your products and manufacture more flexibly.

Compliance

Comply with legal requirements, such as traceability.

A polygonal model of a human body shows technical precision, relevant for Industry 4.0 consulting.
This machine learning project offers a standardized and scalable solution. It not only takes into account the diversity of our products, but also plants that previously planned manually, and integrates them effectively. This synergy of uniformity and flexibility, customized by MaibornWolff, reflects the true value and success of the project.
Dr. Daniel Patrick Kilian, Senior Key Expert Data Science & AI, Digital Industries IT at Siemens

Our performance promise

At MaibornWolff, we understand that a digital transformation can be complex and nerve-wracking - a real change process, in fact.

That's why, as your consultant for Industry 4.0, we don't offer standard solutions, but holistic digitalization with end-to-end support that involves technology and people in equal measure. We accompany companies step by step through the digital transformation - always keeping an eye on the employees.

Put your trust in our expertise and benefit from our Industry 4.0 business consulting services:

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Digital and IT strategy

In just 10 weeks, we work with our partner to develop a viable digital and IT strategy for your company and support the subsequent practical implementation.

Data strategy
Use case identification
Evaluation of solutions
AI in production
Replacement of complex legacy IT systems
Scalable service architectures
Cyber security in production
Immersive digital prototype
ROI calculation
Three people sit at a table outside and work together on a laptop, symbolizing Industry 4.0 consulting in teamwork.

This is what we mean by Industry 4.0 consulting

Strategic advice on digital transformation can provide important impetus for manufacturing companies. However, the bridge from the strategy level to practice is often missing.

Instead of just presentations with dazzling visions of smart factories, we deliver end-to-end solutions for industry - from the initial consultation to the concrete use case. We build highly scalable, automated infrastructures and work with our customers to identify and implement applications that create real added value for the company and its employees. Our employees combine IT and OT expertise. In this way, we close the gap between the two areas and ensure seamless integration of production and IT for our customers.

Would you like to become a satisfied MaibornWolff customer yourself?

Our approach to Industry 4.0 consulting

Industry 4.0 is not just a buzzword - it is the future of production. And we at MaibornWolff are happy to accompany you every step of the way into this future.

Our Industry 4.0 consulting goes far beyond the mere implementation of technologies. We ensure that you acquire the necessary knowledge and skills to work independently and successfully with the new use cases once we have completed our collaboration.

We take a holistic view of the transformation to the smart factory. It doesn't matter whether a company is still at the very beginning or already in the middle of the transformation. We provide support with our services in line with the company's level of digital maturity.

A graphic illustration shows four phases for implementation: Explore, Evaluate, Integrate, Scale, suitable for Industry 4.0 consulting.
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Explore.

A solid strategy is the foundation of any successful transformation. That's why we work with our partners to develop a digital strategy that is in line with your corporate strategy as a first step. This includes

  • Development of concrete measures and an initial prioritization
  • Creation of a detailed schedule
  • A transparent cost overview
  • Design of a tailor-made digital organization
  • Determination of the necessary personnel
  • Support and change management

The focus here is on a future-proof IT/OT strategy and IT architecture and on providing you and your employees with the necessary knowledge to work successfully with it.

Evaluate.

Integrate.

Scale.

Get to know us: Industry 4.0 consulting and engineering: Our workshops

In addition to our comprehensive consulting for Industry 4.0, we also offer specialized workshops that you can take advantage of at any time. Regardless of where you are in the digitalization process, our workshops provide you with targeted support:

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Orientation workshop

Our orientation workshop is ideal for companies that are at the beginning of their digitalization journey and do not yet have a clear idea of how to get started.

  • Duration: 2 days
  • Goal: We give you an initial orientation on the way to your Smart Factory and plan the next steps with you.

Results:

  • Overview of worthwhile Smart Factory use cases with potential analysis
  • Plan for the next steps towards implementation
  • Identification of use cases that bring rapid added value

Benefits for you:

  • Clear orientation & structured planning: support in defining the first steps in the digitalization journey.
  • Rapid added value: Identification of use cases that bring benefits in 1-2 days.
  • Expert knowledge: Access to expertise and experience in the field of IIoT and digitalization

IIoT Solution Assessment

Implementation of a customized IT solution

A man concentrates on his laptop in the office, suitable for Industry 4.0 consulting.

Industry 4.0 consulting - Start your digital transformation with MaibornWolff

Industrial manufacturing in Germany is facing challenges such as demographic change, legal requirements and competition from Asia. MaibornWolff helps you to master these challenges with innovative solutions.

Rely on 9 years of experience and more than 60 successful smart factory projects and let us guide you into the future with the help of Industry 4.0 consulting. For more flexibility, productivity and sustainability in your company.

Two people in intensive discussion, working on technical solutions, supported by Industry 4.0 consulting.
Ready for Industry 4.0 consulting?

Arrange a non-binding consultation today.

FAQ - frequently asked questions about Industry 4.0 consulting

  • What are the challenges of introducing Industry 4.0?

    There are numerous challenges when introducing Industry 4.0. These include a lack of structures and responsibilities within organizations, a lack of high-quality data and qualified personnel, high initial investments in infrastructure and the need for tailored solutions for individual company processes.
  • What does track and trace mean in intelligent manufacturing?

    "Track and trace" in smart manufacturing refers to technologies and processes for tracking and tracing materials, components and products throughout the manufacturing process. This improves control, optimizes production processes and increases quality, efficiency and customer satisfaction.

  • What role do IoT and IIoT play in Industry 4.0?

    IoT and IIoT are central to Industry 4.0, enabling the networking and integration of machines and systems, automatic data collection and processing, and intelligent decision-making and adaptation of manufacturing processes in real time.

  • How do artificial intelligence and machine learning support Industry 4.0?

    Artificial intelligence in industry and machine learning support Industry 4.0 by analyzing large amounts of data, recognizing patterns and providing recommendations for action. They help to continuously optimize processes and prevent problems before they occur.
  • Which IT security and data protection measures are important for Industry 4.0?

    Important IT security and data protection measures in Industry 4.0 include proactive security measures against cyber attacks, compliance with data protection regulations such as the GDPR and new security concepts to prevent data leaks when integrating IT and OT systems. You can find more information in our IT security consulting service, for example.

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