Robert Bosch GmbH / Site Blaichach / Immenstadt (BhP)

At the Blaichach / Immenstadt (BhP) site, Robert Bosch GmbH employs around 4,200 people (as of August 2023) to manufacture products for the automotive industry, including high-tech safety systems and brake boosters. The site, which has been in operation for over 60 years, is divided into the Immenstadt and Blaichach plant sections.

Within its global network of 18 production sites, the INDUSTRIE 4.0 AWARD winner has already established itself as a pioneering Industry 4.0 plant, achieving a high level of maturity in areas such as IT architecture, data availability, standardization, and AI implementation. For the “BPS4.0+” project, which was honored with the INDUSTRIE 4.0 AWARD in 2024, the goal was to leverage existing data—collected over many years—through new and additional methods to achieve the following objectives:

• Increase productivity in machines and manufacturing processes
• Eliminate waste caused by defective parts
• Improve and automate manual work steps
• Ensure consistently high manufacturing quality

The solution is the core element for data-driven improvement and innovation across all 18 plants. Currently, more than 20,000 active IT users interact within this network, integrating indirect functions such as procurement into the core areas of production, logistics, (process) development, and special machine construction.

The Industry 4.0 project focuses on building a data-driven organization in production based on the objectives mentioned above. The key areas of focus are “Technology,” “Know-how,” and “Use Cases,” with a strong emphasis on close collaboration between production employees and data scientists. The primary role of the data scientists is to test and implement use cases related to data analytics and AI applications. However, all use cases are strictly executed under the condition that they provide demonstrable benefits to the respective plant.

Derived from its Industry 4.0 strategy, the INDUSTRIE 4.0 AWARD winner established a standardized IT architecture with a Manufacturing Data Platform (MDP) as its core element. This platform provides data analytics and AI use cases in both a self-service and an expert version. Additionally, all 18 plants follow the same IT architecture standards and operate under a unified governance framework.

To spread knowledge about using the MDP, the site established a “Center of Competence” for the platform, data analytics, and AI. Additionally, an enablement program was created to train data scientists in developing, evaluating, and applying AI models in production.

In a dedicated community, the plants exchange ideas on new use cases. This has fostered a cooperative, open learning culture while keeping the plant’s objectives in focus. All use cases are documented in a standardized tool, where all investments (technology, working hours, etc.) are also precisely recorded. Additionally, the benefits of the measures are calculated based on figures verified by the controlling department.