
Industry 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.
We accompany you from the initial idea through the conception to the complete implementation and operation of the solution.
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.
We ensure that new solutions communicate seamlessly with your existing systems and platforms.
We work with you to define measurable Industry 4.0 use cases and support you in estimating the ROI for your budget planning.
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.

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 unitsLearn more
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 unitsLearn more7 monthsProject duration
Over 20 workshopsThreat analyses
Over 500Potential risks evaluated
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Siemens: AI demand prediction platform for industrial production planningRead more
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 planningRead moreProject 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 assistanceRead more
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 assistanceRead moreProject 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 processRead more
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 processRead moreProject durationsince 2022
Team size2-3 Digital Designer:inside
In 2024Scalix replaces old software -
VW: Digitization of key production figures with the iProcess appRead more
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 appRead moreProject 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 monthsRead more
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 monthsRead more7 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 worldRead more
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 worldRead more<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 InterfaceRead more
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 InterfaceRead moreGoalReplacing 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-creationRead more
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-creationRead moreMost important method:Building an EA community
Created conceptEnterprise Architecture
Cooperationat eye level
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Miele domestic appliances are networked worldwideRead more
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 worldwideRead moreProject durationsince 2016
Success factors:High availability and scalability
IoT platformwith container-based architecture
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MAN: Secure Software Development Life CycleRead more
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 CycleRead more22 monthsProject duration
UNECE R155successfully integratedMethodsSecurity Champions, DevSecOps, OWASP SAMM
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It's LOS: Building a cloud-based low-code applicationRead more
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 applicationRead moreProject durationSince the beginning of 2022
MVPin only 5 weeks
TechnologiesAmplify, AppSync, CodeCommit, IAM, Cognito, DynamoDB, Lambda
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Monitoring alarms in industrial plantsRead more
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 plantsRead more3 yearsProject duration
<3 monthsto the MVP
Cloud migrationModernization & relocation -
Planning systems: Optimizing the capacity utilization of pressing plantsRead more
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 plantsRead more>10 yearsCustomer support
Technological modernizationCloud-ready platformEfficiency through dataSite-specific cost planning -
Global workforce planning systemRead more
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 systemRead moreTeam 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 platformRead more
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 platformRead moreStandardized 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 robotsRead more
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 robotsRead moreMethodProduct 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 systemRead more
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 systemRead moreProject 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 lifeRead more
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 lifeRead more3.2 yearsProject duration
CooperationLocation-independent and virtual
InfrastructureScalable and expandable thanks to the cloud
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BMW Group: Remote software upgrade for vehiclesRead more
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 vehiclesRead more5 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 webRead more
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 webRead more5 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 platformRead more
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 platformRead moreProject durationsince 2016
> 1.000Modules and components in ennexOS platform
> 7.000Fuse tests
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digikoo GmbH: Apple Vision Pro for city plannersRead more
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 plannersRead more4 monthsProject duration
3D map with KPIsDisplay building data dynamicallyEnergy dataImmersive visualization -
digikoo: A data platform for the Azure CloudRead more
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 CloudRead more5 monthsProject duration
Climate changePlan digitally and implement efficiently
Foundation data platformMicrosoft Azure Cloud
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:
Produce faster and more cost-effectively.
Save energy and material.
Detect errors faster and improve quality.
Improve working conditions and reduce manual activities.
Optimize your products and manufacture more flexibly.
Comply with legal requirements, such as traceability.

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.
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:

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.
We help you develop a secure, scalable and flexible data strategy that fits your business goals
We identify valuable use cases that quickly and efficiently add value for your company.
We check your existing smart factory solutions for potential improvements in technology, scalability and security
We support you in the use of AI tools, from the idea to implementation.
We support you in modernizing your legacy systems in order to optimize your supply chain and production processes. We combine OT and IT requirements and manage complex production processes and their dependencies.
We develop IT solutions that adapt to your production processes and take into account the maturity of your organization
We design secure architectures and check your systems for vulnerabilities to minimize risks.
We optimize your design and development processes with digital prototypes.
We support you in calculating and maximizing the ROI of your smart factory use cases. This enables you to accurately assess the profitability of your projects, increase economic efficiency and avoid bad investments.

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.
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.

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.
In this phase, we carry out a maturity assessment that transparently shows the current status of your production. Based on these results, we jointly identify smart use cases and analyze the requirements for their implementation. If you already have a use case, we offer to review the requirements and prerequisites with you and develop them further. This phase includes the following services:
- Technology scouting: The most suitable technologies for implementing the use cases are identified.
- Concept development: Using our extensive toolbox of methods, we develop and evaluate tailor-made concepts for your digital transformation.
- ROI calculation: We are also happy to support you with the ROI calculation and provide you with best practice examples.
- Documentation: We will provide you with the fully evaluated concepts for your use cases and documentation for implementation.
We note that it does not always make sense to digitally map existing processes 1:1. Not all use cases are suitable for every company. We therefore evaluate the proposed solutions in terms of scalability, implementation, security and quality assurance. We also explain the most important terms and technologies in the context of Industry 4.0 and work with you to identify the first quick wins in your production.
Integrate.
If you have already identified relevant use cases, we will of course also support you in implementing them. Together, we analyze processes and data in order to develop use cases that add value quickly and easily. This process includes
- Selecting suitable technologies to implement the use cases
- Design of scalable architectures
- Development of individual IIoT solutions or integration into existing IT/OT landscapes
During implementation, we will be happy to advise you on scaling or enable your employees to further develop or operate the solution we have implemented. As your Industry 4.0 consultant, we can of course also take over the operation of the implemented solution if you do not have the resources to do so.
Scale.
As soon as a minimum viable product (MVP) has been successfully rolled out in the first plant, we support you with scaling. Together, we develop a rollout strategy that defines which features and plants are to be implemented in which phases. Our support includes
- Rollout planning: we help you to roll out your solutions in different plants and countries.
- Knowledge and resource building: We empower your teams through training and education to build the know-how needed for continued success.
- Audits: Through regular audits, we ensure that your use cases are operated economically and securely. In doing so, we identify potential for improvement in the areas of security, operating costs and interoperability.
Thanks to our large pool of experts, which covers a wide range of knowledge from various disciplines, we can scale projects quickly and flexibly and equip them with the necessary skills.
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:

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
Timeframe: 3-8 weeks
Our IIoT Solution Assessment is perfect for companies that already have ideas and requirements but would like to flesh them out further.
- Duration: 3-8 weeks
- Goal: Quickly start implementing a Minimum Viable Product (MVP) with a long-term viable, scalable architecture.
Results:
- Coordinated vision and roadmap
- Prioritization of functions and requirements
- A target architecture and technology stack that meets your requirements in terms of cost-effectiveness, scalability and security
- Detailed planning of the next steps for implementation
Benefits for you:
- Risk minimization: Ensuring technical feasibility and scalability, avoiding the PoC purgatory
- Stakeholder involvement: Greater acceptance and cooperation through early involvement of all stakeholders
- Efficiency: minimizing the risk of failure, shortening time-to-market, saving costs, personnel and time
- Immediate start: possibility to start implementing the MVP immediately
Implementation of a customized IT solution
This offer is aimed at companies that want to implement a specific IT solution for their production.
- Duration: 3-6 months
- Goal: Development and implementation of your IT solution in three phases.
- Phases:
- Requirements engineering: Definition of the MVP scope and ROI calculation.
- Proof of Concept (PoC): Define technology stack and implement PoC.
- Minimum Viable Product (MVP): Go-live of the IT solution and take over operation Our IIoT Solution Assessment is perfect for companies that already have ideas and requirements but want to flesh them out further.
Results:
- Implementation and commissioning of a use case in a pilot plant
- Investment security through ROI calculation and agile approach
- Efficient and resource-saving implementation
Benefits for you:
- Efficiency: Faster presentation of results and lower resource consumption
- User feedback: Faster understanding of challenges and user needs through early user feedback and continuous adjustments
- Risk minimization: Minimization of wrong decisions and bad investments through regular testing

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.

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.