Stuttgart, Germany – November 2026 – BorgWarner, a global leader in automotive powertrain solutions, has announced a 15% increase in production throughput and 28% lower unplanned downtime after deploying the ABB PM825 3BSE010796R1 controller at its transmission component factory in Stuttgart. The upgrade, completed in Q4 2026, addressed critical bottlenecks in the plant’s legacy control system—where outdated PLCs struggled with multi-process synchronization and real-time data processing, costing the company €1.3 million annually in lost output.
The Challenge: Synchronization Gaps and Slow Data Processing
Prior to adopting the ABB PM825 3BSE010796R1, BorgWarner’s Stuttgart plant faced four core operational hurdles:
- Production Line Bottlenecks: Legacy controllers could only process 200 I/O signals per second, causing delays in the transmission gear machining line. This limited the plant to 450 units per shift, falling short of customer demand for 520 units.
- Poor Process Synchronization: Welding, milling, and quality inspection stations operated as siloed systems, leading to 8% of components being misaligned during assembly—requiring costly rework.
- Slow Fault Detection: The old PLCs lacked real-time diagnostic capabilities, taking an average of 45 minutes to identify sensor or actuator failures. This resulted in 120 hours of annual unplanned downtime.
- Incompatibility with Smart Tools: The legacy system couldn’t integrate with new IoT-enabled quality cameras and predictive maintenance sensors, preventing the plant from adopting Industry 4.0 practices.
“Automotive manufacturing demands precision and speed—our old controllers were holding back our digital transformation,” said Markus Weber, BorgWarner’s Plant Operations Director. “We needed a control solution that could handle complex multi-process synchronization while unlocking data-driven efficiency gains.”
ABB PM825 3BSE010796R1: The Smart Core for Automotive Production
After testing competitors from Siemens and Rockwell Automation, BorgWarner selected the ABB PM825 3BSE010796R1 for its high processing power, seamless integration, and rugged design:
- High-Speed Processing: 1.2GHz dual-core CPU processes up to 1,000 I/O signals per second—5x faster than legacy controllers—eliminating line bottlenecks.
- Multi-Process Synchronization: Supports PROFINET IRT (Isochronous Real-Time) communication, synchronizing welding, milling, and inspection stations with ±1ms accuracy.
- Built-In Diagnostics & Predictive Alerts: Integrated self-diagnostic tools detect sensor drift, wiring issues, or actuator failures in 3 seconds, sending real-time alerts to maintenance teams.
- Industry 4.0 Compatibility: Natively connects to ABB Ability™ Manufacturing Operations Management (MOM) system and third-party IoT devices (cameras, vibration sensors) via OPC UA/Modbus TCP.
- Rugged Industrial Design: Operates in -25°C to +70°C temperature range with IP20 protection, withstands vibration from machining equipment, and requires no additional cooling.
Results: Throughput Surges and Downtime Plummets
Six months post-deployment, BorgWarner’s Stuttgart plant achieved transformative results:
| Metric |
Before ABB PM825 3BSE010796R1 |
After ABB PM825 3BSE010796R1 |
Improvement |
| Production Throughput |
450 Units/Shift |
518 Units/Shift |
15% Increase |
| Unplanned Downtime |
120 Hrs/Year |
86 Hrs/Year |
28% Reduction |
| Rework Rate |
8% |
2.3% |
71% Reduction |
| Data Processing Speed |
200 Signals/Sec |
1,000 Signals/Sec |
400% Improvement |
| Annual Cost Savings |
— |
€980,000 |
Direct ROI |
“The PM825 3BSE010796R1 has become the nervous system of our production line,” Weber said. “We’re now hitting customer demand without sacrificing quality, and the predictive alerts have turned unplanned downtime into scheduled maintenance.”
Stefanie Klein, ABB’s Global Product Manager for Industrial Controllers, highlighted the controller’s fit for automotive manufacturing: “Automotive plants need controllers that can keep up with fast-paced, complex processes while enabling smart factory initiatives. The PM825 3BSE010796R1 delivers the speed, reliability, and connectivity that drives tangible operational gains.”
BorgWarner plans to deploy the ABB PM825 3BSE010796R1 across 3 more European plants by 2027, targeting a group-wide 12% increase in production efficiency.
