Variety of options for connected manufacturing: Bosch presents Industry4.0 solutions

From a single source: software, sensors, and machinery

  • People and machinery work together safely and flexibly
  • Software detects deviations and ensures quality
  • Connected transport crate minimizes production stoppages
  • Industry 4.0 has become broadly established in practice

Hannover and Stuttgart, Germany – Bosch is presenting a large number of solutions for connected manufacturing at Hannover Messe 2016 (hall 7, booth C18). The exhibits at the booth are digitally connected and exchange data. The benefits to customers along the value chain are clearly evident, and include continuous quality control and reduced energy demand.

Here are a few selected examples:

Sensors use real-time information to improve logistics
The sensor solution known as “TraQ” (track quality) uses real-time information to improve logistics. During transport, sensors in the packaging or on the product itself record information that is relevant for quality – such as temperature, vibration, light, and humidity levels – and send it to the Bosch IoT Cloud . A Bosch software application in the cloud compares the readings with permitted levels. If there is any deviation, an alert is triggered that informs customers, suppliers, and service providers in real time. In this way, the connected transport box detects vibrations that are too strong and reports them to the owners and insurance companies. The point at which the damage occurred and what caused it are immediately known, which benefits the transport of sensitive goods, such as semiconductors and delicate laser technology. If the delivery of machine parts is delayed, notifying the customer at an early stage may mean that they are still able to make alternative arrangements. The benefit: timely notification minimizes downstream costs, such as production stoppages, in the case of damage to goods. The sensors are scheduled to go on sale beginning in mid-2017.

High degree of process reliability: ActiveAssist guides workers through production
The modular ActiveAssist manufacturing system, which can be flexibly adapted, is especially useful for simplifying the assembly of multi-variant products. Step by step, it guides workers through the individual manufacturing phases on a monitor. Using RFID (radio frequency identification), the system identifies the workpiece to be machined and provides information about the necessary process steps. For example, the system uses light signals to mark the storage containers that contain screws and other parts for the next process step, thus ruling out incorrect hand movements or the use of incorrect parts. This leads to greater process reliability and helps reduce workload. The system can be customized in line with the worker’s level of knowledge, experience, and preferred language. The workstation can also be quickly converted to accommodate new products.

Real-time control with the Process Quality Manager enhances quality
The Process Quality Manager software solution records and analyzes data from assembly processes in real time, and identifies trends and deviations. Workers are immediately notified of potential problems. As a result, they can take corrective action at an early stage, and in this way ensure consistent quality. One application is the continuous quality control of safety-critical screw connections, such as those used in the automotive industry. The Bosch Nexo connected cordless nutrunner records the torque applied during the screw-tightening process, among other things, and transmits this data to the Process Quality Manager software. The software recognizes in real time whether the screw-tightening process was carried out correctly. Deviations are immediately apparent, and the appropriate experts are notified directly. The data generated by the cordless nutrunner can be shown on the ActiveCockpit, which is an oversized display in the manufacturing shop. Thanks to the clear charts and diagrams, workers remain up to date on the current state of the manufacturing process at all times. Workers and companies alike benefit, because a problem with screws that are slightly too small or too large, for example, is immediately identified. In turn, downtime is reduced, the quality of the products increases, and potential recall costs are avoided. Details about Process Quality Manager: Details about Nexo:

Intelligently connected workstation ensures highest possible productivity
The mobile production assistants of the APAS family are making a further contribution to greater productivity in industrial manufacturing. They are easy to program and can be used flexibly in production. The family is welcoming a new member at the Hannover Messe: the APAS workstation. This intelligently connected workstation combines a work surface, a collaborative robotic arm, and a monitor that displays work instructions. Thanks to its sensitive sensor skin, the robotic arm immediately stops whenever someone gets too close. People and machines can therefore work together without guards. As a result, the system creates new possibilities for teamwork between machines and workers. The employers’ liability insurance association has certified the APAS as safe for direct collaboration with people. The other family members: The APAS inspector is an optical inspection system that uses automatic image processing to examine surfaces and check workpieces for completeness and correct dimensions. The APAS flexpress is the perfect helper for joining, stamping, shaping, or punching workpieces. Like the other members of its family, the APAS assistant can also be quickly adapted to meet new tasks without requiring users to have programming skills. Together with the sensor skin, its robotic arm is also offered individually as APAS safekin, allowing customers to use it in their own applications. Thanks to the APAS family, the customer benefits from quickly adaptable automation for the smart, flexible factory. Details about APAS:, APAS booth in hall 7, D04.

Sensor kit is the “midwife” for new Industry 4.0 applications
What if someone has an idea for an internet of things (IoT) or Industry 4.0 application, but does not yet have the technical means to implement it? With the XDK development kit, Bosch is offering precisely that: a comprehensive hardware and software platform featuring different types of sensors as well as Bluetooth and wi-fi connections. Bosch is helping its customers get their own IoT or Industry 4.0 business ideas ready for full-scale production as quickly as possible. It features a range of components, including an acceleration sensor, a yaw-rate sensor, a magnetometer, and sensors for measuring atmospheric pressure, air temperature and humidity, noise levels, and light. Proprietary software helps with processing and displaying data, and the XDK community is there to help with questions. Details:

Energy platform uncovers savings potential
Energy costs are a significant factor affecting competitiveness, and this not only in manufacturing. Bosch’s energy platform provides a comprehensive overview of energy consumption in buildings and production processes. The platform is managed with a browser-based user interface, and energy consumption and costs can be evaluated quickly and intuitively thanks to customizable graphs and diagrams. It is possible to display the energy requirement for any machine on a shop floor, providing a real-time overview of the heat, cooling, or compressed air needed. Based on this information, the consumption levels of individual machines can often be reduced, resulting in cost savings. Bosch provides a one-stop solution with its energy platform software and hardware.

Data analytics boosts competitiveness
The data from connected manufacturing contain huge amounts of information. Used correctly, it offers great potential for optimized production processes and enhanced competitiveness. Bosch’s manufacturing analytics tools and services software addresses precisely this objective, lending support in data collection and analysis, otherwise known as data mining. As a result, it can reduce production-related costs. Bosch is specialized in problems that arise in manufacturing and provides analysis tools and predictive models. Customers can take advantage of this without their own analytics expertise. Details about manufacturing analytics tools and services:; details about data mining at Bosch:

Fewer instances of unplanned downtime: software triggers machine maintenance
Many machines are equipped with their own software or sensors that are already able to provide information about the machine’s condition or a given production step. With the help of the Bosch Production Rules Configurator software, it is possible to quickly and conveniently create rules for analyzing this data in a useful way and for initiating activities for improvement. For example, a rule can prompt a maintenance cycle if a wear trend has been identified, thereby avoiding unplanned downtime. The software helps to convert people’s experience into rules for connected manufacturing. Details:

Tags: Solutions, Industry 4.0,

About Bosch

The Bosch Group is a leading global supplier of technology and services. It employs roughly 402,000 associates worldwide (as of December 31, 2017). The company generated sales of 78.1 billion euros in 2017. Its operations are divided into four business sectors: Mobility Solutions, Industrial Technology, Consumer Goods, and Energy and Building Technology.

As a leading IoT company, Bosch offers innovative solutions for smart homes, smart cities, connected mobility, and connected manufacturing. It uses its expertise in sensor technology, software, and services, as well as its own IoT cloud, to offer its customers connected, cross-domain solutions from a single source. The Bosch Group’s strategic objective is to deliver innovations for a connected life. Bosch improves quality of life worldwide with products and services that are innovative and spark enthusiasm. In short, Bosch creates technology that is “Invented for life.” The Bosch Group comprises Robert Bosch GmbH and its roughly 440 subsidiary and regional companies in 60 countries. Including sales and service partners, Bosch’s global manufacturing, engineering, and sales network covers nearly every country in the world. The basis for the company’s future growth is its innovative strength. At 125 locations across the globe, Bosch employs some 64,500 associates in research and development.

The company was set up in Stuttgart in 1886 by Robert Bosch (1861-1942) as “Workshop for Precision Mechanics and Electrical Engineering.” The special ownership structure of Robert Bosch GmbH guarantees the entrepreneurial freedom of the Bosch Group, making it possible for the company to plan over the long term and to undertake significant upfront investments in the safeguarding of its future. Ninety-two percent of the share capital of Robert Bosch GmbH is held by Robert Bosch Stiftung GmbH, a charitable foundation. The majority of voting rights are held by Robert Bosch Industrietreuhand KG, an industrial trust. The entrepreneurial ownership functions are carried out by the trust. The remaining shares are held by the Bosch family and by Robert Bosch GmbH.

Additional information is available online at,,,

Still looking for something?