Digitalization with a major impact
Success Story
How Webasto is building the foundation for predictive maintenance and sustainable production with connACT
Introduction
Industrial manufacturing is facing new challenges due to shorter product life cycles, growing product and process complexity, and increasing pressure to improve resource efficiency.
To remain competitive, intelligent production solutions are needed. Crucial elements include digitally connected systems, reliable databases, and the ability to immediately react to deviations and exploit potential.
This is where connACT SERVICES, a SITEC service ecosystem, comes in. It offers a modular range that combines traditional industrial services and digital solutions. A central element is connACT ADVANCED, a digital Overall Equipment Effectiveness (OEE) tool that makes machine and process data visible in real time, creating the basis for well-founded decisions.
This collaboration shows how Webasto achieves measurable added value with this solution.
Digital retrofit on Webasto's shop floor
Webasto is a global system supplier to the automotive industry. Headquartered in Stockdorf, Bavaria, Webasto specializes in roof systems, battery-powered electrification, and thermal management solutions.
At its Neubrandenburg site in Mecklenburg-Western Pomerania, Webasto manufactures electric and fossil fuel-powered parking heaters for original equipment and the aftermarket. These products are primarily used in passenger cars and commercial vehicles.
In 2022, the first production system developed by SITEC at the Neubrandenburg plant was equipped with connACT. The integration was completed within a short amount of time. Immediately after commissioning, the first measurable optimization potential was uncovered: Fewer downtimes, lower reject rates and increased process stability.
"In the past, we faced the challenge of precisely specifying errors that occurred on the systems during the shift, especially on the shop floor. The connACT system makes these errors visible, so we can react promptly and effectively." – Sven Kretzschmar, Manufacturing & Engineering, Webasto
Thanks to successful cooperation and customer satisfaction, connACT was extended to all SITEC systems. Today, this digital solution is an integral part of Webasto's continuous process optimization.
Systematically improving energy efficiency
Another key component of connACT is integrated energy monitoring. Consumption of resources such as electricity and compressed air is recorded, analyzed, and visualized in real time.
At Webasto, the system provides transparency about current energy consumption and enables the identification of potential savings during operation. Based on the collected data, measures to reduce energy consumption were defined and successfully implemented.
The benefits are clear: lower operating costs, optimized resource usage, and a step closer to sustainable production.
Condition monitoring and predictive maintenance
With connACT, central machine and system parameters can also be continuously monitored.
Webasto uses condition monitoring to evaluate the condition of its production systems in real time. By identifying process anomalies early on, maintenance measures can be planned more effectively. This has significantly reduced the NOK rate.
This predictive maintenance strategy increases the technical availability of machines while reducing maintenance costs. In this way, connACT establishes the foundation for greater process reliability and minimizes the risk of costly production downtime.
Added value through data intelligence
The project with Webasto in Neubrandenburg demonstrates how connACT contributes to the data-driven optimization of manufacturing processes. This innovative solution helps manufacturing companies improve system performance, reduce operating costs, and create more sustainable processes.
"In the future, we want to use connACT for all systems from other manufacturers at our plant. We want to display a uniform level of information for all systems on the shop floor to further increase production efficiency," Kretzschmar emphasizes.
Since 2020, all new SITEC systems have come equipped with the OEE tool. However, existing systems from other manufacturers can also be easily retrofitted.
Contact
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About SITEC
SITEC is a world-renowned partner and system supplier of automated, high-tech production facilities, as well as the series production of precision parts and assemblies.
Adhering to the highest quality and environmental standards, SITEC provides efficient manufacturing technologies and comprehensive turnkey solutions.
The company develops production-ready solutions for automated assembly, laser material processing and electrochemical metal processing for customers across the globe in the automotive, medical technology and alternative energy technology industries. The company achieves this with a team of around 300 highly qualified employees.
SITEC rises to the challenges faced by its customers and the market, such as developing new products in the field of e-mobility and self-sufficient storage technologies based on fuel cells. The portfolio now includes fully automated laser processing systems for laser welding, particularly of copper for components in electric drives, battery systems, and power electronics.
Since 2012, the company has also been producing laser-welded bipolar plates of various designs in series production on behalf of customers.
Founded in 1991 and headquartered in Germany, SITEC serves Asian markets directly through its subsidiary, SITEC Laser Technology (Shanghai) Co. LTd., and operates a showroom in Pittsburgh, USA.
Contact
Communications and Marketing
SITEC Industrietechnologie GmbH
Bornaer Straße 192
09114 Chemnitz
Germany
Phone: +49 371 4708 241
Fax: +49 371 4708 240
Email: marketing@sitec-technology.de