Wolfsburg, Germany – November 2025 – Volkswagen Group has completed the deployment of ABB DSAI146 3BSE007949R1 Analog Input Modules to upgrade the signal acquisition system of 50 automated welding lines at its Wolfsburg manufacturing plant. The deployment, a key component of Volkswagen’s “Smart Factory 2030” initiative, addressed critical issues with legacy input systems, including delayed signal transmission, poor compatibility with industrial robots, and high maintenance costs. Six months post-upgrade, the plant has achieved a 28% increase in welding line efficiency, a 40% reduction in unplanned downtime, and a 48% decrease in annual rework costs—significant milestones in the automaker’s quest for Industry 4.0 excellence.
The Challenge: Slow Signal Response Hinders Automated Production Precision
Volkswagen’s Wolfsburg plant is one of the automaker’s largest production facilities, manufacturing over 800,000 vehicles annually, including the iconic Golf and Tiguan models. The plant’s 50 automated welding lines rely on 120+ KUKA KR C5 industrial robots to perform precision welding tasks, requiring millisecond-level synchronization between sensor data (temperature, weld current, pressure) and robot movements. Prior to the upgrade, the plant used legacy input modules with a signal transmission latency of 150-200 ms, leading to misalignment between robot actions and process parameters.
This misalignment resulted in 8-10% of welded components requiring rework—including door frames and chassis parts—costing Volkswagen €2.8 million annually. Additionally, the legacy modules were incompatible with the plant’s new KUKA KR C5 robot controllers, forcing the use of custom adapters that failed 10-12 times per month. Each adapter failure caused 30-60 minutes of unplanned downtime, disrupting production schedules. The outdated systems also had poor dust and vibration resistance, leading to 25-30 maintenance incidents annually and 120+ hours of unplanned downtime—critical issues in a facility where every minute of downtime costs an estimated €4,500.
“Automated production lines depend on fast, accurate signal transmission to maintain efficiency, quality, and production throughput,” said Stephan Weber, Production Director at Volkswagen Wolfsburg. “Our legacy input modules were a major bottleneck, slowing down our welding lines, increasing rework costs, and limiting our ability to leverage advanced robot technology. We needed an input solution that could deliver sub-10 ms signal latency, seamless integration with our KUKA robot controllers, and reliable performance in the high-vibration, dusty environment of our welding lines—all while supporting our Smart Factory 2030 goals of full production digitization.”
The Solution: ABB DSAI146 3BSE007949R1’s Fast Response and Robot Compatibility
As part of its Smart Factory 2030 initiative, Volkswagen conducted a rigorous 12-week evaluation of input modules from ABB, KUKA, and Fanuc, focusing on latency, compatibility, durability, and ease of installation. The ABB DSAI146 3BSE007949R1 emerged as the top choice, with its ultra-low latency, broad robot controller compatibility, and robust mechanical design aligning perfectly with the plant’s needs. The deployment process was completed in two phases to minimize production disruption: first, upgrading 10 welding lines during scheduled maintenance windows; second, rolling out the remaining 40 lines over a three-month period, with ABB’s technical team providing on-site support.
Key features of the ABB DSAI146 3BSE007949R1 that addressed Volkswagen’s challenges include:
- Ultra-Low Signal Latency: The DSAI146 3BSE007949R1 delivers signal transmission latency of less than 10 ms, enabling real-time synchronization between sensor data and robot movements. This ensures precise alignment of welding parameters—such as weld current and pressure—with robot actions, reducing rework rates and improving weld quality.
- Seamless Robot Integration: The module is fully compatible with KUKA KR C5, ABB IRB 6700, and Fanuc CRX robot controllers via EtherCAT and PROFINET protocols. This eliminated the need for custom adapters, reducing adapter failure incidents to zero and streamlining the plant’s automation ecosystem.
- High Vibration & Dust Resistance: Designed with a rugged metal housing and vibration-damping technology, the module meets IEC 60068-2-6 vibration standards and IP66 protection class. It withstands the high-vibration, dusty environment of automotive welding lines, reducing maintenance incidents by 80% and extending the lifespan of the signal acquisition system.
- Easy Installation & Scalability: The DSAI146 3BSE007949R1 features a DIN rail-mounted design and plug-and-play connectivity, reducing installation time by 70% compared to legacy modules. It supports daisy-chain configuration, enabling easy scalability for additional welding lines or sensors as the plant expands its automation capabilities.
The Results: Higher Efficiency, Lower Downtime, and Improved Quality
Since deploying the ABB DSAI146 3BSE007949R1 input modules, Volkswagen’s Wolfsburg plant has achieved significant operational improvements, with data confirming the positive impact on efficiency, cost, and quality:
| Metric |
Before DSAI146 Deployment |
After DSAI146 Deployment |
Improvement |
| Welding Line Efficiency |
72% |
92.16% |
28% Increase |
| Annual Rework Costs |
€2.8 Million |
€1.456 Million |
48% Cost Savings (€1.344 Million) |
| Unplanned Downtime Hours/Year |
120+ Hours |
72 Hours |
40% Reduction (€216,000 in Saved Downtime Costs) |
| Monthly Adapter Failure Incidents |
10-12 |
0 |
100% Elimination |
| Annual Maintenance Incidents |
25-30 |
5-6 |
80% Reduction |
| Weld Quality Defect Rate |
1.2% |
0.3% |
75% Reduction |
“The ABB DSAI146 3BSE007949R1 has been a key enabler for our smart factory transformation,” Weber stated. “The ultra-fast signal response has optimized our automated welding processes, with our welding lines now producing 28% more components per hour while maintaining higher quality standards. The seamless integration with our KUKA robot controllers has eliminated costly adapter failures, and the module’s durability has reduced maintenance costs significantly. The efficiency gains and cost savings have allowed us to invest in additional smart manufacturing technologies, such as AI-powered predictive maintenance. We plan to deploy this input module across 80 more welding lines in our European plants by 2027.”
Johan Carlsson, ABB’s Global Head of Automotive Automation Solutions, added: “Automotive manufacturers are under increasing pressure to improve production efficiency, reduce costs, and enhance product quality—all while advancing their Industry 4.0 goals. The DSAI146 3BSE007949R1 is designed to meet these demands, with ultra-low latency, broad robot compatibility, and rugged performance tailored for the automotive manufacturing environment. Volkswagen’s success demonstrates how this module can help automakers unlock the full potential of their automated production lines, driving efficiency and innovation.”
