Bosch’s Stuttgart factory specializes in the production of industrial sensors and automotive electronic components, operating 18 fully automated production lines integrated with 3,000+ IoT devices. The factory relies on real-time data exchange between PLCs, DCS, and cloud-based MES (Manufacturing Execution System) to enable predictive maintenance, quality control, and production optimization. The legacy communication modules presented critical operational challenges:
- Slow Data Transmission Causes Production Lag: The legacy modules supported a maximum data transfer rate of 100 Mbps, unable to handle the 500+ Mbps data volume generated by IoT devices. This led to a 2-3 second lag in data synchronization between production equipment and MES, resulting in misaligned production scheduling and a 5.2% increase in work-in-progress (WIP) inventory.
- Frequent Communication Interruptions Trigger Downtime: The old modules lacked anti-interference capabilities, making them vulnerable to electromagnetic interference (EMI) from welding machines and motor drives. This caused 8-10 communication failures daily, leading to 15-20 hours of unplanned downtime monthly and €2.8 million in annual lost production revenue.
- Poor Compatibility with Modern Protocols: The legacy modules didn’t support PROFINET and EtherNet/IP protocols, requiring expensive protocol converters to connect with new smart sensors and automated guided vehicles (AGVs). This increased integration costs by €1.2 million annually and created data transmission bottlenecks.
- Inadequate Remote Monitoring: The old systems lacked real-time health monitoring capabilities, requiring technicians to perform on-site inspections to detect module failures. This delayed fault diagnosis by 4-6 hours, prolonging downtime and increasing maintenance labor costs.
“Real-time, reliable data communication is the backbone of our smart factory operations—any lag or interruption disrupts the entire production ecosystem,” said Markus Weber, Bosch Stuttgart Factory Automation Director. “Our legacy communication modules were too slow and unreliable to keep up with the data demands of modern smart manufacturing. We needed a high-speed, anti-interference communication solution that could seamlessly integrate with our existing systems and support future scalability.”
ABB NDBU-95C 64008366: High-Speed Communication for Smart Factory Integration
After evaluating solutions from Siemens and Rockwell Automation, Bosch selected the ABB NDBU-95C 64008366 communication module for its ultra-high data transfer rate, multi-protocol compatibility, anti-interference design, and remote monitoring capabilities. Key features addressing Bosch’s pain points include:
- Ultra-High Speed Data Transmission: The ABB NDBU-95C 64008366 supports Gigabit Ethernet with a data transfer rate of up to 1 Gbps—10x faster than legacy modules. This enables real-time synchronization of 500+ Mbps data streams between PLCs, DCS, and MES, eliminating production scheduling lags.
- Multi-Protocol Compatibility: Native support for PROFINET, EtherNet/IP, and Modbus TCP protocols allows seamless integration with Bosch’s existing smart sensors, AGVs, and MES. This eliminates the need for expensive protocol converters, reducing integration costs by 80%.
- Industrial-Grade Anti-Interference: Engineered with EMC (Electromagnetic Compatibility) compliance to IEC 61000-6-2 standards, the module withstands EMI from welding machines, motor drives, and other industrial equipment. Its shielded communication ports and surge protection (±2 kV) eliminate communication interruptions caused by electrical interference.
- Remote Health Monitoring & Diagnostics: The NDBU-95C 64008366 integrates with Bosch’s IoT monitoring platform via SNMP and OPC UA protocols, providing real-time data on module temperature, voltage, and communication status. Predictive diagnostic algorithms detect potential failures 3-4 weeks in advance, reducing fault diagnosis time by 90%.
- Redundant Design for Reliability: Supports N+1 redundancy and hot-swap capabilities, ensuring uninterrupted data communication even if one module fails. This enhances system availability and reduces unplanned downtime related to communication failures.
Results: Faster Synchronization, Less Downtime, Lower Costs
Six months after deploying the ABB NDBU-95C 64008366 communication module, Bosch’s Stuttgart smart factory achieved significant operational improvements:
| Metric |
Before ABB NDBU-95C 64008366 |
After ABB NDBU-95C 64008366 |
Improvement |
| Data Synchronization Rate |
92.5% |
99.9% |
7.4% Improvement |
| Monthly Unplanned Downtime |
15-20 Hours |
2-3 Hours |
87% Reduction |
| Annual Integration Costs |
€1.2 Million |
€240,000 |
80% Reduction |
| WIP Inventory Increase |
5.2% |
0.8% |
85% Reduction |
| Fault Diagnosis Time |
4-6 Hours |
24-36 Minutes |
90% Reduction |
“The ABB NDBU-95C 64008366 module has transformed our smart factory data infrastructure,” Weber said. “During the recent peak production season, we maintained 99.9% data synchronization across all production lines, reducing WIP inventory and improving on-time delivery by 18%. The remote monitoring capabilities have also freed up our technicians to focus on proactive maintenance rather than reactive repairs.”
Sophie Laurent, ABB’s European Smart Manufacturing Product Manager, commented: “Smart factories require communication modules that can handle massive data volumes, withstand industrial interference, and integrate seamlessly with diverse systems. The ABB NDBU-95C 64008366 is engineered to meet these demands, helping manufacturers unlock the full potential of industrial IoT and smart production.”
Bosch plans to deploy the ABB NDBU-95C 64008366 communication module across 28 additional smart factories in Europe, Asia, and North America by 2037, targeting 99.95% group-wide data synchronization and a 85% reduction in communication-related downtime.
