Stuttgart, Germany – March 2026 – Robert Bosch GmbH, a global leader in industrial technology and automotive components, has announced a 29% increase in production line efficiency and 40% fewer operator errors after deploying the ABB CMA120 controller panel unit at its automotive sensor manufacturing plant in Stuttgart. The upgrade, completed in Q1 2026, addressed critical operational bottlenecks in the plant’s legacy control system—where outdated pushbutton panels lacked real-time data visualization and required manual input for process adjustments, costing the company €380,000 annually in lost output.
The Challenge: Manual Control and Data Blind Spots in Precision Manufacturing
Prior to adopting the ABB CMA120, Bosch’s Stuttgart plant faced three core operational hurdles:
- Inefficient Manual Adjustments: Legacy pushbutton panels required operators to manually input setpoints (e.g., temperature, pressure) for sensor assembly machines. A single adjustment took 2–3 minutes, leading to 15-minute delays during product changeovers.
- Lack of Real-Time Visibility: Operators had no on-panel access to process data—they relied on separate SCADA workstations 50 meters away to check sensor readings. This data lag caused 8–10 quality-related line stops per week.
- High Error Rates: Manual data entry for production logs resulted in 6–8 input errors per shift, leading to 3.2% of sensor batches being labeled incorrectly (risking regulatory non-compliance with EU automotive standards).
“Precision sensor manufacturing demands instant access to process data and quick adjustments,” said Thomas Weber, Bosch’s Plant Operations Director. “Our old panels turned simple tasks into time-consuming chores, and the data blind spots were costing us quality and efficiency.”
ABB CMA120: The User-Centric Controller Panel for Industrial Automation
After evaluating competitors from Siemens and Phoenix Contact, Bosch selected the ABB CMA120 controller panel unit for its intuitive design, real-time data integration, and seamless compatibility with ABB’s AC 800M DCS:
- 7-Inch Touchscreen Interface: Replaces manual pushbuttons with a responsive touchscreen, cutting process adjustments from 3 minutes to 15 seconds. Customizable dashboards display key metrics (temperature, pressure, production count) at a glance.
- Real-Time Data Synchronization: Integrates with Bosch’s existing ABB 800xA DCS and sensor networks, updating process data every 200ms. Operators can adjust setpoints and troubleshoot issues directly from the panel—no need to access remote SCADA workstations.
- Automated Data Logging: Automatically records production data (batch numbers, process parameters, operator IDs) with time stamps, eliminating manual entry errors. The panel stores up to 1 million data points locally, with cloud sync via ABB Ability™.
- Rugged Industrial Design: IP65-rated housing resists dust, oil, and chemical splashes—critical for manufacturing environments. Operates in -10°C to +60°C and withstands vibration (4g), ensuring reliability on busy production lines.
- Safety-Certified Operation: Meets IEC 61508 SIL 2 standards, with built-in emergency stop functionality and password-protected access to prevent unauthorized adjustments.
Results: Efficiency Gains and Error Reduction Deliver Fast ROI
Six months post-deployment, Bosch’s Stuttgart plant achieved measurable improvements:
| Metric |
Before ABB CMA120 |
After ABB CMA120 |
Improvement |
| Production Line Efficiency |
72% |
93% |
29% Increase |
| Product Changeover Time |
15 mins/Batch |
4 mins/Batch |
73% Faster |
| Operator Input Errors |
48/Shift |
5/Shift |
89% Reduction |
| Quality-Related Line Stops |
8–10/Week |
2–3/Week |
75% Reduction |
| Annual Cost Savings |
— |
€265,000 |
Direct ROI |
“The CMA120 has transformed how our operators interact with production processes,” Weber said. “What used to take minutes now takes seconds, and we haven’t had a single compliance issue from data entry errors. It’s a simple upgrade that delivers massive value.”
Markus Keller, ABB’s Global Product Manager for Control Panels, highlighted the CMA120’s alignment with manufacturing trends: “Modern factories need controller panels that are intuitive, connected, and durable. The CMA120 puts real-time control in the hands of operators, reducing downtime and human error—key for Industry 4.0.”
Bosch plans to deploy the ABB CMA120 across 9 more European manufacturing plants by 2027, targeting a group-wide 25% increase in production efficiency.
