Smart lighting management and digital services via networked luminaires

Trilux, the German market leader for technical luminaires, is facing the challenge of adapting its production processes to the requirements of Industry 4.0. In the face of increasing competitive pressure from Asia and growing customer demands for customised products, the company decided to take the strategic step towards a smart factory. Together with adesso, the company embarked on the path to digitally supported production in order to sustainably increase efficiency and flexibility.

Trilux was confronted with several challenges:

• High competitive pressure from Asian market players.
• Increasing customer requirements for customised luminaires.
• The need to ensure efficient and low-defect production.

The aim was to digitalise the production processes and at the same time ensure employee acceptance on the shop floor.

The ‘OptiMa’ (Optimised Manufacturing) project was launched to establish digitally supported production at Trilux. A key component was the introduction of a worker guidance system. This is a user-friendly system that supports workers in production. As early as the conception phase, we worked closely with employees to develop a solution that is optimally tailored to the needs of the shop floor.

The SAP Business Technology Platform (BTP) forms the technical basis of the system. The platform offers modular functions and comprehensive integration options, creating a flexible and scalable toolbox for production. The solution is characterised by the following features:

• Ease of use:
  Large control elements and intuitive interfaces that can also be operated with gloves.
• Flexibility:
  Connection of different machines and devices such as scanners or torque wrenches.
• Stability:
  Establishment of reliable interfaces and fallback scenarios for high operational reliability.

The worker guidance system is now an integral part of the production processes at Trilux. Not only has it significantly reduced the error rate and throughput time, it has also increased transparency throughout the entire production process. Sales staff can now trace products back to assembly, which significantly improves quality assurance.

Results at a glance:

Trilux benefits from a future-proof and flexible production infrastructure that not only strengthens competitiveness, but also opens up potential for future innovations. The key benefits include