The client, recognized for its innovation in advanced vehicle production, faced the challenge while operating complex, robot-driven production lines. The company relies heavily on virtual commissioning to validate machines, robots, and workflows before physical deployment.
With growing system complexity and increasing data volumes, the manufacturer needed a scalable, intelligent way to manage engineering knowledge across tools, teams, and production environments.
To modernize virtual commissioning and reduce engineering complexity, we implemented an AI-powered knowledge platform to unify data, accelerate troubleshooting, and enable digital twin–like insights. By integrating intelligent search, knowledge graphs, and conversational AI directly into existing engineering workflows, the solution eliminated data silos and significantly improved commissioning speed, reliability, and decision-making.
Meet Our Client
The client is a German manufacturing company known for producing luxury automobiles and motorcycles. It operates globally with production facilities in over 15 countries and is recognized for its precision engineering, innovative technologies, and commitment to sustainability, aiming for climate neutrality by 2050.
Its factories use advanced automation and flexible production systems, allowing for efficient and high-quality manufacturing. Through its strong focus on performance and design, it maintains a leading position in the automotive industry.
Case Study Shortcut
Challenge
Fragmented Knowledge and Data Silos
Engineering data was distributed across PLM systems, SharePoint, ERP platforms, CAD repositories, robotic simulation tools, and legacy IT systems. Locating the right documentation for a single production cell was slow and inefficient.
Missing Context Between Components and Systems
Engineers lacked a unified view showing how individual components—such as sensors, motors, or PLCs—impacted machines, robots, and entire production lines.
Slow Troubleshooting and Decision-Making
Tracing dependencies during virtual commissioning was time-consuming, often resulting in delays, rework, and increased risk before go-live.
Ineffective Search Experience
Traditional keyword-based search returned incomplete or irrelevant results. Engineers needed a context-aware, conversational way to retrieve information.
Goal
The project’s primary goal was to accelerate and de-risk virtual commissioning by creating a single, intelligent knowledge layer across all engineering systems.
- Unify fragmented manufacturing and engineering data
- Enable context-aware, natural language search
- Visualize dependencies across machines, robots, and production lines
- Reduce troubleshooting time and engineering effort
- Provide a digital twin–like experience without rebuilding existing systems
Outcome
The implementation delivered immediate and measurable improvements across engineering and commissioning teams.
- Virtual commissioning cycles became significantly faster, with engineers able to access connected data and validate designs in seconds instead of hours.
- AI-powered search and knowledge graphs dramatically improved transparency and confidence, enabling teams to identify issues earlier and make better-informed decisions before physical deployment.
- The solution also strengthened collaboration by embedding intelligence directly into existing tools such as Slack and Microsoft Teams.
Before
- Engineering data scattered across disconnected systems
- Manual searches taking 30+ minutes
- Limited visibility into component interdependencies
- High risk of errors discovered late in commissioning
After
- Unified, searchable engineering knowledge base
- Critical information accessible in seconds
- Interactive visualization of production line dependencies
- Issues identified earlier, reducing downtime risk
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Case Study Details
Approach
Unified AI Knowledge Graph
- Connected parts, machines, robots, production lines, and documentation into a single, continuously updated graph
- Mapped real-world dependencies between components, systems, and workflows
Context-Aware Search & Conversational Access
- Enabled natural language search across PLM, CAD, ERP, and control systems
- Applied intelligent ranking and AI-generated summaries to surface critical engineering insights
- Provided chat-based access to knowledge, troubleshooting, and report generation
Digital Twin–Like Visualization
- Delivered graph-based visualization of production environments and system relationships
- Enabled interactive exploration of dependencies and change impact analysis
Integration with Virtual Commissioning Tools
- Connected the knowledge platform with simulation and virtual commissioning software
- Supported real-time validation of production line changes before physical deployment
Scalability & Real-Time Accuracy
- Ensured continuous synchronization of documents and system changes
- Designed an enterprise-scale architecture supporting multiple teams and production lines
