- Project reference
Smart Factory
Digital concept for smart water meters
Challenges
Lorenz wanted to set up a new, efficient production line for smart wireless water meters in order to improve its market prospects in the face of international competition. The plan was to set up a production line in collaboration with ITQ, whilst ITQ’s sister company, Software Factory, was to develop the integrated production management and line control system.
The challenge was to network the entire production system, including the existing IT infrastructure, in order to manufacture digital devices quickly, flexibly and in an environmentally friendly manner. This involved integrating various IT systems and standardising data structures from planning right through to the shop floor to ensure secure, digitally controlled manufacturing.
ITQ Solution
ITQ has been involved in the implementation of the Smart Factory since its very beginnings in 2015, covering everything from concept development through control systems, HMI and integration right through to project coordination.
The system that has been implemented is based on IoT functionalities for IT security, process data processing, traceability, visualisations and smart apps, with the aim of standardising the new forms of decentralised information provision from the planning stage right down to the shop floor. The digitally controlled production process was implemented in a 1,000 m² production hall built in 2022.
Results & Benefits
Lorenz is thus able to produce almost 2 million water meters per year, involving around 20 process steps – from hydraulic assembly and programming through to calibration, individual testing and packaging. Thanks to the latest IoT functionalities, it is possible, where necessary, to intervene quickly and precisely in the control of the production lines, reduce sources of error and disruption, compare process flows and find effective solutions to problems.
Further benefits:
- Production flexibility right down to batch size 1 (i.e. individually configurable)
- Short delivery times
- High quality and transparency throughout the process
With this digitalisation strategy, Lorenz GmbH & Co. KG has risen from being a ‘hidden champion’ to a technology leader in smart metering and has been honoured with, amongst other accolades, the Digital Leader Award and the MOVECO Innovation Award as part of the European Union’s (EU) Interreg programme.
FAQ
What was the main challenge of the project?
The biggest challenge was to set up a fully networked production environment that both integrates existing IT systems and enables end-to-end data structures from planning right through to the shop floor.
What solution was implemented?
A smart factory has been implemented, based on IoT technologies and integrating functions such as IT security, process data processing, traceability, visualisation and decentralised information provision.
What role did ITQ play in the project?
ITQ was involved in every aspect of the project – from concept development, through control systems and HMI, to integration and project coordination – throughout the entire project.
What specific results were achieved?
The production line enables the manufacture of up to 2 million water meters per year across some 20 process steps, whilst ensuring high levels of efficiency, quality and transparency.
What added value does the solution offer the customer?
The Smart Factory enables flexible production down to batch size 1, shorter lead times, rapid intervention in production processes and a significant reduction in errors and disruptions.
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