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How Industry 4.0 is making production at wienerberger more efficient, more reliable and more sustainable with automated data collection, digital twins and predictive analytics – and what that means for our customers.
Filipp Pühringer, Head of Industry 4.0 at wienerberger and his team have a clear goal. “A plant should run smoothly, just like a precision clock. The key to achieving this is our digitalization strategy which we pursue single-mindedly. This approach not only improves our production – it also benefits our customers.“
“A plant should run smoothly, just like a precision clock."
What sounds simple enough is in reality a highly complex undertaking since there are more than 200 plants, over 500 production lines, and thousands of machines and processes that have to be perfectly coordinated. Keeping them all operating smoothly requires more than modern technology. It also needs sound data, an understanding of how the data from the sub-systems involved in production is interlinked and above all, a willingness to challenge familiar processes. This is where wienerberger’s digitalization strategy comes in.
wienerberger’s digitalization strategy encompasses three levels:
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The digital transformation process at wienerberger begins with the automated collection of all relevant production data. These days, wienerberger’s central database records 172,800,000 data points from more than 500 machines at over 50 sites daily – ranging from production speed to machine capacity, temperature and pressure to the number of pieces produced. This data is collected and stored on a cloud platform where it forms the “digital twin” – a virtual replica of a physical machine or production line that is updated in real time. Previously invisible aspects are now visible and measurable thanks to the digital twin. These virtual replicas of physical objects, systems and processes give the company in-depth insights into production processes and machinery and enable it to track their performance in real time. This provides an actionable knowledge base for improvement processes to increase performance and efficiency.
The digital twin offers wienerberger advantages on multiple levels:
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Digital twins have been in use at wienerberger since 2020 – with noticeable success. The solution brand Pipelife, for example, has been able to reduce its material input by using digital twins. Sensors immediately detect if a product is too heavy and an intuitive, graphical representation enables rapid intervention and targeted optimization of the production process.
Digital twins are also used in brick production. “The process signals tell us exactly how much gas is used in the production of one ton of bricks. This information is then used to train data models that show us which parameters we can use to reduce gas consumption, for example”, explains Filipp Pühringer.
Digitalization thus not only increases efficiency, it also has a direct impact on wienerberger’s Sustainability Targets.
However, the advantages of digitalization are not restricted to the company. Customers also benefit from greater reliability, the prevention of bottlenecks and predictable delivery dates. In addition, they receive products with a smaller carbon footprint – a factor that will play a crucial role in the regulatory environment in years to come, regardless of any positive contribution to reducing global emissions.
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The aim is to record relevant data at all production sites and for an increasing number of application areas – from machine uptimes to consumption data, order data, formulas and occupational safety statistics – and to consolidate this data in management reports. This enables us to digitally monitor and manage our processes – from raw materials procurement to ordering and delivery – via a cockpit to make production more efficient.
The collected data is not only valuable in the present. It is already being used to automatically create consolidated reports that furnish insights into current production processes as well as information on deviations and potential for improvement. These reports provide the Operational Excellence teams with an important basis for decision-making and facilitate the development of data-driven benchmarks.
In the near future, it will be possible to produce accurate data-based predictions with the help of artificial intelligence and advanced data analytics. AI can identify crucial correlations between process parameters, key performance indicators and the ecological footprint, thus creating the basis for real-time, data-driven decision making. “We rely on data-based decision making: Instead of merely reacting to changes, we want to manage our processes proactively and systematically, for example, with a view to sustainably reducing the amount of energy we use in production”, explains Filipp Pühringer.
„We rely on data-based decision making: Instead of merely reacting to changes, we want to manage our processes proactively and systematically, for example, with a view to sustainably reducing the amount of energy we use in production.“
Digital Maintenance: Efficiency through Foresight
Digitalization also offers huge potential with regard to the maintenance of production facilities. The digital maintenance tool, for example, enables measures to be planned efficiently and distinguishes between three different approaches. Corrective maintenance is carried out after a fault or failure has already occurred. Preventive maintenance is performed at regular intervals to prevent faults or failures before they happen and does not depend on the actual operational condition of the equipment. Predictive maintenance on the other hand, uses sensor data and data models to monitor the state of the systems in real time and to predict when maintenance will be needed, thus preventing unexpected equipment failures.
“Predictive maintenance is another lever for greater efficiency and less unplanned downtime. It helps minimize unanticipated issues in the production process, thus ultimately improving delivery reliability for our customers even further. Workers at the production plants appreciate stress-free operations and the company values the savings it makes on spare parts since these are only used where needed!“, says Filipp Pühringer.
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The digital transformation at wienerberger begins and ends with well-maintained master data, since this is the basis for every data-driven decision – in areas ranging from production planning to supply chain optimization. Continuous and effective maintenance of data on materials and machines, such as formulas, production capacities and speed, or information on recycling rates and material reorder points, is essential if errors are to be avoided and processes managed efficiently.
Outdated or incorrect master data not only leads to production problems; it can also jeopardize delivery deadlines and ultimately customer relationships. Master data must therefore be seen as a strategic asset – not as a tedious chore. This requires clear ownership and a group-wide awareness that digital excellence is only possible with reliable data.
Digitalization is also playing an increasingly central role in supply chain management. Even today, electronic data interfaces (Electronic Data Interchange, EDI) allow key customers to enter their orders directly into the SAP system. But this is just the beginning: wienerberger is further developing its supply chain services in a more differentiated way — with a stronger focus on the individual needs of its customers.
One example: As part of an increasingly networked and intelligently controlled production system, wienerberger is working with a major customer toward a vendor-managed stock (VMS) model. In this setup, wienerberger takes responsibility for managing the customer’s inventory, controls replenishments based on predefined minimum and maximum stock levels, and thereby provides noticeable relief for the customer.
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At wienerberger, Industry 4.0 encompasses far more than just production. “Integrating data collection into our products also represents a significant opportunity”, explains Filipp Pühringer.
wienerberger has therefore launched a company called Wioniq that develops data-driven solutions for managing and monitoring water and energy infrastructure and optimizing building operations. Seamlessly networked devices record all key system parameters and analyze them via a platform to provide actionable recommendations and manage operating processes. This increases efficiency and reliability and reduces operating costs, resource consumption and emissions.
Additional opportunities in this area have been created by the acquisition of the roof and photovoltaic solutions supplier Terreal: “In future, solar modules in combination with sufficient storage capacity and smart control could actively contribute to grid stability by recognizing when, where, and how much electricity should be fed into the grid. This would turn every grid participant into an energy producer, trader and consumer – all depending on the grid situation and load profile“, says Filipp Pühringer.
With more than 200 production plants, implementing industry 4.0 at wienerberger is a complex, but strategically important task. Through the targeted digitalization of our processes, we are shaping this transformation step by step – with the aim of making our production smarter, more efficient, and more sustainable. Despite all the technical challenges, it is people – our employees, customers, and society – who remain at the heart of our digital transformation.
>> Learn more about the digital transformation at wienerberger in an Interview with Franz Lesiw, SVP Group IT & Digitalization.
