“The future of manufacturing begins with smart retrofitting, not necessarily with a new machine."
Martin Preiss, Managing Director, DVS Service
Existing machines are transformed into intelligent production systems.
DVS combines measurement technology, data analysis, and machine control into an automated quality cycle that brings existing machines up to the level of modern manufacturing. Process deviations are detected in real time, automatically corrected, and thoroughly documented—resulting in greater productivity, less scrap, and self-optimizing quality.
Lack
of Connectivity
Machines, tools, measurement technology, and data do not interact as an integrated system and do not unlock the full potential of manufacturing.
Significant
staffing requirements
High labor requirements, frequent tool changes, and occasional manual quality checks have, until now, limited efficiency and process autonomy.
Investment Pressure
Scrap, rework, and the perceived need for new machines lead to unnecessarily high costs.
For an international automotive manufacturer, an existing production line was to be upgraded for largely autonomous 24/7 operation. High labor requirements, regular tool changes, and sporadic quality monitoring had previously limited efficiency and process autonomy. What was required, therefore, was not a traditional one-off retrofit, but rather a comprehensive concept that intelligently integrates productivity, quality assurance, and autonomous process control.
DVS Service and DVS Digital developed an integrated solution combining mechanical and electrical adjustments—DVS Edge—high-resolution optical measurement technology, and automated twin-die operation. The integration with the customer’s evaluation software created a seamless information and control loop. The integrated closed-loop tool correction automatically converts detected deviations into tool corrections, thereby reducing the need for manual intervention during the ongoing manufacturing process.
The number of staff required was reduced by 60%, while the optimized tooling process enables approximately 85 minutes of additional machine runtime per shift. At the same time, output increased to 1,814 components per shift. At the same time, quality assurance has been significantly expanded: Instead of sporadic inspections of a few characteristics, a dual 100% inspection of approximately ten quality characteristics is now performed—ensuring greater process stability, transparency, and reliability in series production.
The Results for the Client
-60% personnel costs:
1.0 instead of 2.5 employees per shift.
+255 minutes:
additional machine operating time per day (across three shifts).
+147 parts:
increased daily output. 5,442 parts instead of 5,295 parts at 92% output.
Higher process reliability:
Through 100% inspection and automatic corrections.
Let’s work together to explore how your plant can be further developed through retrofits, measurement technology, and digital process control—from individual optimizations to a largely autonomous manufacturing process.