Do you want to automate your processes more?

The digital transformation in production and plant engineering opens up new possibilities. How can you benefit from these? We from Fraunhofer IESE are happy to support you.

Automation in Production and Plant Engineering

Is your company already responding to the current developments on the world market, and do you already address issues such as the digital transformation, Industrie 4.0, and predictive maintenance? The question is: How to use these innovations best, both for yourself and for your company, in order to generate market and competitive advantages?

The business area Automation of Fraunhofer IESE is the first point of contact for industrial manufacturing companies as well as for mechanical and plant engineers who want to further develop and optimize their production, technologies, processes, or products through software-based and digital innovations and align them to Industrie 4.0.

In numerous industry projects, our researchers have contributed and proven their expertise in the areas of Big Data, Processes, Architecture, Security, Safety, Requirements Engineering, and User Experience.

Are these your challenges in production and plant engineering?

  • Digitalization of the manufacturing processes to enable automated production
  • Changeable production down to lot size 1
  • Documentation of products and processes
  • Shorter manufacturing times through optimized automation
  • Cost reduction and quality increase in production and plant engineering
  • Live streaming of manufacturing data
  • Efficient process monitoring
  • Increase in productivity
  • Holistic overview of manufacturing (shop floor and office floor)
  • Optimization of coordination and efficiency between IT and Manufacturing
  • Virtual commissioning in mechanical and plant engineering

Get in touch with us. The experts from Fraunhofer IESE will develop the right solution with you.

Flexibility in production through efficient automation solutions

At present, individuality is becoming increasingly important in our society. This change is also reflected in customers’ purchasing behavior. As a result, the need to be able to manufacture a wide variety of products and product variants with high efficiency is becoming more and more urgent. This requirement must also be reflected in the manufacturing processes. Although today’s manufacturing processes are very efficient, they are usually inflexible.

Changing the product type can therefore entail a great deal of effort and thus high costs. Potential customers that want to produce small lot sizes are faced with high unit costs, which may jeopardize the economic feasibility of their projects.

The transition to Industrie 4.0 promises to remedy this situation. By making production processes more flexible, the product type can be changed quickly and cost-effectively. This enables economically feasible manufacturing of orders even with lot size 1 and thereby increases competitiveness. In addition, the use of previously unused production process data enables completely new insights.

But how should this transition to Industrie 4.0 take place? It requires an efficient automation solution – in the form of software –that supports flexible workflows in a manufacturing process.

Fraunhofer IESE will develop a customized solution for you as well. Benefit from us as your partner on your way to Industrie 4.0.

Typical issues in manufacturing

  • How to implement changeable production?
  • How to develop Digital Twins and how to use them?
  • How to establish open, highly networked automation systems that enable data access across several layers of the automation pyramid and even across companies?
  • How to enable the use of state-of-the-art information technology concepts such as Big Data in automation?
  • How can the paradigm change from embedded systems to cyber-physical systems take place?
  • How to tap data sources for predictive maintenance?
  • How to integrate devices from different manufacturers into a homogeneous communication system?

Are you dealing with these issues? Do you have further questions? Talk to us!
Below, we present a solution with the technology-independent middleware BaSys. 

The automation solution for your manufacturing

Fraunhofer IESE - Automation with Middleware BaSys

In the BMBF-funded research project BaSys, Fraunhofer IESE, together with 14 other partners* from the field of production technology, has developed concepts and solutions for realizing Digital Twins as digital representations for production. This has resulted in a basic system for production facilities that enables efficient changeability of a production process as a central challenge of the fourth industrial revolution. The aim was to network and integrate existing technologies in such a way that Industrie 4.0 applications can be implemented to achieve greater automation. For this purpose, the project developed a virtual middleware that allows providing and linking the necessary services. In doing this, central concepts of Industrie 4.0, such as the Digital Twin in the form of the asset administration shell, have been implemented.


The benefits of BaSys for shop floor and office floor

  • Provision and implementation of central Industrie 4.0 concepts as an open-source project
  • Easy development of Digital Twins via defined interfaces
  • Change of production within minutes, not months
  • Enabler for lot size 1
  • Easy integration of existing facilities as well as new devices
  • Access to process data from the office floor
  • Ready-made reference components for fast commissioning
  • Predictive maintenance on the shop floor


Our project partners

*The following partners are involved in the project together with Fraunhofer IESE:

ABB Ltd., Bosch Rexroth AG, DFKI GmbH, Eclipse Foundation, Engrotec, Festo AG & Co. KG, FORTISS GmbH, ITQ GmbH, Fraunhofer IOSB, Ifak, KUKA Roboter GmbH, Lenze, PSI Automotive & Industry GmbH, Rheinisch-Westfälische Technische Hochschule (RWTH) Aachen, Robert Bosch GmbH, SMS Group GmbH, SYSGO AG, ZF Friedrichshafen AG 

Selected automation projects


BaSys – The Open-Source Middleware for Industrie 4.0

Making Industrie 4.0 easy! BaSys is a basic system for production plants. As a virtual middleware it allows providing the required services on the shop floor and the office floor and linking these with each other. Find out more about the project here.



In the research project FabOS, Fraunhofer IESE is involved in developing an open, distributed, real-time-capable, and safe operating system for production in an Industrie 4.0 “Smart Factory”.



In the research project PROPHESY, Fraunhofer IESE collaborated with twelve project partners on the easy introduction of predictive maintenance solutions for the creation of new business models.


Siemens Gas and Power GmbH & Co. KG

Gaining new knowledge from data - that was the aim of the joint project between Fraunhofer IESE and Siemens Gas and Power GmbH & Co. KG.


SPES_XT: Software Platform Embedded Systems “XT”

While the complexity of embedded systems is increasing rapidly, innovation cycles are becoming ever shorter. This trend can now also be observed increasingly in safety-relevant applications.


Sick AG Success Story

Together with Fraunhofer IESE as a partner, SICK AG has developed a method for reusing modular function blocks and the software implemented from them in safety-critical sensor systems.

Meet us at the important events of the automation industry

Please feel free to contact us in advance and arrange a personal meeting.

Hannover Messe 2021 – The world’s leading trade fair for industry

12.  - 16. April 2021, Hannover Messegelände

Focus: Topics such as Industrie 4.0, Logistics 4.0, Artificial Intelligence, 5G, and CO2-Neutral Production are on the agenda at this world-leading trade fair, as are lightweight construction solutions and the evolution of electric drives.

With the new lead topic Industrial Transformation and about 6,000 exhibitors, the world-leading industry trade fair will focus on the opportunities arising from the new technologies, changed demand patterns, and increasing awareness for climate protection.

Further information