Industrial Internet at Bosch ConnectedWorld

Chicago, Sept. 27-28 During this two-day event, you will learn about and experience Industrial Internet solutions from Bosch and other innovative partners. You will see technologies and best practices gained from applying connected manufacturing solutions across the value chain.

BCW Chicago

Shop floor transparency

Workers on the shop floor require access to a wide variety of data – from long-term production planning data to real-time data about recent events, e.g. current availability of staff, products, and tools. Making information from multiple IT systems digitally available to shop floor staff is a key prerequisite for lndustry 4.0, as is providing a way to capture data digitally on the shop floor.

Our solutions for enabling shop floor transparency:

Interactive communication platform - Rexroth ActiveCockpit

It networks IT applications such as production planning, quality data management, e-mail, and personalized calendars with the software functions of machines and plants. The information serves as a basis for decision and process optimization.

Rexroth ActiveCockpit

lndustry 4.0 approach

  • Real-time collection, processing, and visualization of all relevant data of a manufacturing facility for the exchange of information between man, machine, and production processes on the shop floor
  • Interactive software for the diagnosis and optimization of systems and processes as well as fault management
  • Browser-based internet standards and accommodation of third-party applications
  • Easy connection to various back-end systems (MES/ERP)


  • Higher productivity through digitally supported continuous process improvement, integrated fault management, and higher resource efficiency due to improved planning
  • Fast and efficient decisions through updated and consistent key figures
  • lncreased transparency in production and real-time access to all relevant data for each person directly on the line
  • Time savings by eliminating manual data collection and analysis
  • Scalable end devices, from mobile devices up to large multi-touch displays

Current solution

  • Time-consuming, labor-intensive data maintenance
  • Large amount of space required
  • Limited support for interactive solution rounds

Connected solution, I4.0

  • Connected to MES, ERP, DB
  • Paperless communication
  • Moderation, escalation, and whiteboard functions
  • Open system via app platform
Connected Solution i4.0
ActiveCockpit Image

Learn more about ActiveCockpit and the advantages it offers

Optimizing the use of process tools in manufacturing – from tracking to tracing

The Track & Trace testbed is designed to help optimize the use of tools for processes such as riveting, tightening, welding, and measurement. The tracking component lets you locate tools on the shop floor, thus improving tool utilization and boosting quality. Geofencing can be used to ensure that only the right tool with the right configuration is used in the designated work cell. The solution’s tracing component helps capture usage data from the tools, e.g. by analyzing sensor data generated directly by the tools. By combining positioning information with production data, the right tool configuration can be automatically activated in real time. Similarly, quality lots can be created that merge localization data as well as process data, e.g. torque and angle for tightening processes.

Track and Trace

Rule-based analysis of production data

The Production Rules Configurator is a software solution that makes it easy to translate know-how into rules for evaluating production data (process and machine data) in order to trigger the required action in the event of deviations or trends. It can be tailored to the specific needs of each individual user in their production environment.


lndustry 4.0 approach

  • Rapid and smooth implementation for data acquisition
  • Software for flexible rule-based analysis of production data
  • Automated analysis of process and machine data (24/7)
  • Simple graphical modeling of rules by manufacturing experts
  • Central repository for capturing expert knowledge
  • Customized configuration and scaling


  • Early detection of deviations: gives you time to take action to safeguard production quality
  • Support dynamic maintenance intervals: perform machine maintenance only if and when production data so indicates
  • Simple, customized implementation: the manufacturing expert creates and customizes the rule model

Industry 4.0 with the Production Rules Configurator

Michael Eisenbart, lndustry 4.0 project manager in car-injector production, discusses how the Bosch plant in Homburg has realized lndustry 4.0 by using the Production Rules Configurator. He explains how this software for manufacturing experts is used in production processes for rule-based analysis of production data. This allows the user to react more quickly to deviations and faults and thus prevent production downtime or loss of quality.

White paper: Rule-based analysis of production data – manufacturing experts at the heart of lndustry 4.0

lndustry 4.0 is making manufacturing increasingly smarter, more flexible, and more transparent. The most significant role in this changing environment is played by people – they are the creators of the factory of the future. How can software provide the best support in this context?

Find out more by reading our free white paper: 

  • How can you make your factory smart? 

  • Why are people at the heart of this process? 

  • What are the key criteria for software designed for manufacturing experts? 

  • How can the rule-based analysis of production data help in this context?

The white paper provides detailed answers to all these questions and offers some examples of applying the rule-based analysis of production data. We hope it will help you take the next steps on your journey toward the smart factory.


Process quality

Being able to identify and classify small problems in the production process before they actually cause much larger problems further on in the process is a critical capability. Modern process tools provide the intelligence necessary for capturing and processing the relevant process data as the foundation for significant process quality enhancements.

Our solutions to enable process quality:

Wireless-enabled tightening system: Rexroth Nexo

With their integrated control system, Nexo wireless-enabled cordless nutrunners work in networked environments, communicating with higher-level systems via a browser-based operating system. They are also suitable for safety-critical Class A couplings in accordance with VDI/VDE2862.

Rexroth Nexo

Industry 4.0 approach

  • Workpiece-dependent parameters for couplings support a wide range of assemblies, guaranteeing quality
  • Integrated control system with browser-based operating system for multi-vendor sharing of information with higher levels
  • Easy integration into assembly lines without any additional control hardware
  • Ergonomically optimized with digital assistant functions


  • Cost-efficient and safe couplings for small- and large-batch quantities
  • Documentation of all processing parameters for digital lifecycle management
  • Simple connection to higher-level systems without additional hardware
  • Ergonomically optimized display for user-friendly information and a high-precision measuring system for accurate torque and angle detection

Learn more about the Nexo and the advantages it offers

Managing process data – the intelligent way

The Process Quality Manager visualizes, monitors, and documents process data in real time, automatically detects process deviations and trends, and helps experts optimize production processes directly and on an ongoing basis. It is instrumental in achieving zero defects, transparency, and the best quality production output. One typical use case is in safety-critical tightening processes.


Industry 4.0 approach

  • Transparent factory: overview of all tightening processes
  • Central collection of all relevant process and quality data
  • Processing and visualization of real-time data
  • Expert as the key player: being proactive instead of reactive in response to potential process deviations
  • Web-based interface: access to data from wherever you are via PC or mobile device
  • Open interface so that devices/controls can be connected regardless of the manufacturer
  • Role-specific provisioning of information


  • Early detection of process risks: enables preventive measures and thus avoids failure costs
  • Faster reaction to process errors: reduces failure and reworking costs, results in more output
  • Continuous process transparency: supports continuous improvement and enhances utilization of specialist knowledge

Industry 4.0 – Process Quality Manager for safety-critical tightening processes in the cloud

Dr. Werner Struth presents one of the first Industry 4.0 applications that will be available on premise and accessible via web browser in the IoT cloud marketplace – no installation required. The Process Quality Manager visualizes, monitors, and documents process data in real time. This joint solution by Bosch Rexroth and Bosch Software Innovations helps detect and avoid deviations as early as possible.

Product variety

“Variety kills capacity” – the old operations research saying still holds true for most manufacturing organizations. Finding efficient ways for dealing with high levels of product variety, in combination with ever smaller batch sizes and increasing pressure for just-in-sequence production, is another key requirement for successful Industry 4.0 strategies.

Our solutions for enabling product variety:

Worker assistance system – Rexroth ActiveAssist

ActiveAssist brings together people, equipment, and processing through distributed intelligence. The web-based software and standardized interfaces precisely identify workpieces and support employees for a wide range of assembly variants. At the same time, it monitors the quality of the process and initiates corrective action. ActiveAssist can be expanded with additional modules.



  • Shorter processing times and reproducible quality in a wide range of assembly variants
  • Standardized interfaces enable easy commissioning and integration with MES/ERP systems
  • Intuitive user interface and optimized ergonomics for broad worker acceptance
  • Customized products can be manufactured faster and more efficiently

Worker guidance

Projection of work instructions, marking of the grab container (pick by projector) or the assembly position.

Nutrunner positioning

Ultrasonic technology gives the position of the nutrunner at any time. The operator can start the process only once the tool is in the correct position.

Product identification

Product identification: RFID used to identify the product variant and to upload the right working plan, process data, and components.

Interactive Worker Instructions

Touchscreen or virtual button for interaction with the operator and for work instructions display.

Hand tracking

Depth-sensing camera for real-time detection of hands without any wearables.

Engineering efficiency in automation

Based on open standards, software tools, function toolkits, and the Open Core Interface, Open Core Engineering combines high engineering efficiency in automation with the technologies and tools of the IT world. Based on open standards, these solutions enable machine builders and end users to implement new services and business models.


BenefitsOCE Logo

  • High engineering efficiency in PLC automation with technology-oriented toolbox components for easy adaptation to machines and processes
  • Scalable control solutions with decentralized intelligence units for an extensive portfolio of automation control and drive functions
  • Combined PLC and IoT applications via Open Core Interface
  • "Multi-Ethernet"-based communication and support of standardized web & IT technologies
OCE Image
OCE Image

Learn more about Open Core Engineering and the advantages it offers

Flexible automation

The ability to combine manual processes with automated processes is key to enabling product variety and small batch sizes. Being able to leverage robotic capabilities to support human workers can also have a very positive effect on the work environment, because it helps reduce highly repetitive or physically challenging work steps.

Our solutions for enabling flexible automation:

Changeable automation with the APAS family

As manufacturing moves toward Industry 4.0, companies have to be able to react to new market requirements in real time; this requires faster, more flexible machines and facilities. That’s why Bosch has introduced the APAS family: an innovative manufacturing concept for the flexible factory. With its mobile, intrinsically safe, and networkable process modules, you can rapidly adjust fluctuating batch sizes, integrate additional processes, and configure agile manufacturing islands.

APAS Family

How can the APAS family support you as you move towards the flexible factory?

The APAS assistant, APAS flexpress, and APAS inspector are standardized production assistants that, either as stand-alone solutions or combined in a cell, allow for:

  • ad hoc small-series production
  • partial automation
  • pilot production to ensure process validity
  • agile engineering with early interim results
  • quality tests
APAS Assistant

Hand in hand with the APAS assistant – direct, safe, and collision-free collaboration

The APAS assistant is the first collision-free assistance system that allows direct collaboration with people without additional safeguards. The system supports humans in production by taking over monotonous or ergonomically challenging tasks:

  • handling tasks such as palletizing, sorting, loading, and unloading
  • tooling tasks by working with other tools
  • documentation tasks, such as recording, evaluating, assigning, and delivering image data using its integrated 3D image processing system

Universal gripper

The APAS assistant’s sensitive three-finger gripper enables frictional and form-fit gripping of components and products. Force and stroke control allow the gripper fingers to grasp objects smoothly and firmly. In the event of a collision, the gripper fingers bounce to avoid trapping the object.

Watch video on YouTube

Quick-release casters

Its quick-release casters mean the APAS assistant can easily be moved around in a production environment. There is no need to bolt it down at the workstation.

Watch video on YouTube

User interface

The APAS assistant is operated with a mobile touchpad. On the dialog-controlled user interface, the operator can configure new work plans even without any programming knowledge. These plans are stored and can be retrieved at any time.

Sensor skin

The robot arm is covered by a highly sensitive sensor skin, which reacts immediately when a person approaches. Before there can be any contact between that person and the machine, the APAS assistant stops completely and continues its work only once the person is out of harm’s way. The APAS assistant is the first collaborating robot system to be certified for industrial use.

Watch video on YouTube

Camera system

With its 3D-image processing system and the lighting integrated into the camera head, the APAS assistant is able to detect objects and the workstation within a room. Furthermore, image recognition enables precise gripping and placement, which minimizes the requirements for part feeding.

Watch video on YouTube

APAS speedswitch

Maximum performance combined with maximum safety: with this option, the APAS assistant can monitor its surroundings and work at maximum speed. As soon as someone enters its immediate vicinity, the APAS assistant automatically switches to a safer speed.

Watch video on YouTube

Precision and dynamics with the APAS flexpress – your strong partner for joining tasks

The APAS flexpress is a mobile production assistant for highly flexible and high-precision joining. Its side plates can be quickly and easily adjusted for different-size workpieces, allowing for fast and precise execution of:

  • various joining tasks
  • stamping
  • forming
  • embossing
APAS Flexpress

Planar stage

Parts that are to be joined can be moved to the press ram using the APAS flexpress planar stage. With no further handling, these parts can be joined directly on the planar stage. The system can be altered to handle different-sized workpieces using adjustable side plates.

Watch video on YouTube

Joining unit

The APAS flexpress enables fast and precise execution of various joining tasks. In addition, the task range includes staking, embossing, stamping, and forming. The APAS flexpress is available in a 2 kN or 5 kN configuration.

Watch video on YouTube


The integrated safety concept protects the user against incorrect operation and its consequences. The joining process can be started only once the safeguards are fully in place.

Quick-release castors

Its quick-release casters mean the APAS flexpress can easily be moved around in a production environment. There is no need to bolt it down at the workstation.

Watch video on YouTube

User interface

The APAS flexpress is operated using a mobile touchpad.

Watch video on YouTube
APAS Inspector

An eye on everything with the APAS inspector – competent solutions for your testing tasks

The APAS inspector is a mobile visual inspection system for the shop floor. Thanks to its modern image processing technology, it can be flexibly configured for the requirements specific to various visual inspection tasks:

  • inspections of matte and glossy surfaces
  • completeness checks
  • dimensional accuracy checks
  • learning image processing

Variable test modules

Several different test modules are available, each of which can be manually exchanged. They feature especially robust 3D-imaging processes, thus making both highly sensitive surface inspections and completeness checks possible.

Watch video on YouTube

3D imaging

A high-resolution, high-speed camera with lighting and innovative 3D methods records all optical characteristics relevant to quality. Mounted in an adjustable and sturdy base frame, the camera can be flexibly aligned and adapted to various test tasks. You can switch between various recording modes and choose different lighting options to accommodate a nearly unlimited number of variations.

Watch video on YouTube

Planar stage

On the planar stage, the test samples are transported directly under the camera, scanned in increments, or, depending on the configuration, rotated beneath the camera. Thanks to this flexibility, the operator can carry out a multitude of different tests beneath the camera merely by changing software parameters –and without making any mechanical changes.

Watch video on YouTube

User interface

The APAS inspector is operated by means of a mobile touchpad. The user interface shows test results as well as process images.

Watch video on YouTube

Quick-release casters

Its quick-release casters mean the APAS inspector can easily be moved around in a production environment. There is no need to bolt it down at the workstation.

Watch video on YouTube

Learn more about the APAS family

Thanks to all Bosch partners

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Industrial Internet at Bosch ConnectedWorld

Chicago, Sept. 27-28 During this two-day event, you will learn about and experience Industrial Internet solutions from Bosch and other innovative partners. You will see technologies and best practices gained from applying connected manufacturing solutions across the value chain.

BCW Chicago