AUMOVIO and plus10: Optimizing automated production in mega factories for large automotive displays

As part of the DIAZI project, AUMOVIO and plus10 are setting new standards for automated electronics and display production in AUMOVIO's mega factories in Czechia, Romania, and Serbia. The basis for this is plus10-Shannon®, an intelligent shop floor assistance system. Shannon® collects high-frequency machine data and provides real-time situational recommendations for plant operators, shift supervisors, maintenance teams, and production engineers around the clock. Its implementation at AUMOVIO's plant in Brandýs, Czechia, has already contributed to an increase in availability of up to 5% in the production of large display assemblies.

In recognition of its commitment to AI-powered manufacturing innovation, AUMOVIO's mega factory in Brandýs has been accepted into the World Economic Forum's Global Lighthouse Network in Davos, demonstrating its leadership in using cutting-edge technologies to set new industry standards.

The challenge: Why industrial automation needs intelligence

In highly automated factories, unplanned machine downtime, short stops, and cycle time deviations are among the biggest obstacles to operational efficiency. Several areas for improvement were identified in the production and final assembly of large displays at AUMOVIO in order to further increase performance and productivity.

The large number of short stops clearly showed that a data-driven approach to troubleshooting was needed to reduce dependence on experience, intuition, and manual troubleshooting. The introduction of automatic root cause analysis significantly reduced the mean time to repair (MTTR) and increased the mean time between failures (MTBF) – indicators of greater stability and efficiency throughout the entire operation.

In addition, the manual bottleneck identification process used to date did not provide complete transparency regarding the causes of downtime, which meant that effective countermeasures were not always possible. Without real-time insights into dynamically changing production bottlenecks, optimization potential along the line often remained untapped—and with it, opportunities for systematic improvement.

Operation as key: plus10-Shannon® integrated into AUMOVIO's highly scalable edge-to-cloud IT platform.

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Enabler: Cross-plant scalable manufacturing IT – independent of local requirements

As a key step in its digital transformation, AUMOVIO implemented a highly scalable, standardized IT infrastructure called AUMOVIO Edge2Cloud in 2023—a core element within a DIAZI work package. This enabled the seamless integration of machine networks at each location and the use of data-driven optimization tools that require both high-frequency real-time data from all machine controls (PLC, RC, NC) and a powerful cloud environment.The plus10-Shannon® tool was implemented as a two-tier architecture that combines latency-critical data processing on edge devices – both physical and virtual – with a powerful, near real-time cloud analytics platform.

Flexible edge device ecosystem as part of the AUMOVIO Edge2Cloud standard platform

Since the individual plants in the global AUMOVIO production network manufacture different product solutions, there are various location-dependent IT/OT infrastructure solutions that are either already in productive use or still in the pilot and evaluation phases. AUMOVIO's Edge2Cloud platform is designed to integrate this heterogeneous system landscape and supports the use of a wide variety of shop floor for low-latency applications – from simple Linux-based VMs or industrial PCs (e.g., plus10 DataCollector) to advanced, centrally managed edge solutions. As part of an ongoing equipment initiative, additional machines and lines are continuously being equipped with these edge devices to run latency-critical applications directly at shop floor.

For effective system utilization, Shannon® was configured for each production line using PLC project files from 10 to 15 controllers (PLCs) or robot controllers (RCs). The system, which processes signals in the millisecond range, was then trained with high-frequency real-time data from all connected machine controllers in order to precisely model the actual plant behavior.

Based on this, Shannon® now provides real-time recommendations, including root cause analysis of faults, situational troubleshooting solutions, bottleneck analysis, and categorization of typical errors and warnings. The first implementation in the final assembly lines for large displays at the Brandýs plant was completed within six weeks and resulted in an increase in availability of up to 5%.

Operational excellence in production – made possible by Shannon®

Shannon® is role-based, enabling the tool to address the specific requirements of different user groups in manufacturing and increase efficiency and transparency in operational production:

• Line managers: gain real-time insights into downtime and bottlenecks for effective countermeasures and monitoring of anomalies.

• Maintenance teams: benefit from automatic notifications about the causes of malfunctions, which speed up troubleshooting and optimize maintenance planning.

• Plant operators: receive situational recommendations for action in the event of downtime and simplified knowledge exchange in their preferred language.

• Production engineers: use real-time analyses of bottlenecks, PLC cycle times, and causes of quality losses to optimize productivity and cycle times.

• Process engineers: gain transparency regarding quality and process deviations and receive notifications about critical parameter changes.

Results and impact

Just a few weeks after implementation, the use of Shannon® led to a significant increase in availability, a reduction in short stops, and optimized cycle times for the lines. The data-driven approach enabled the production teams to move from manual troubleshooting to proactive optimization.

Felix Müller, CEO of plus10, emphasized:

Shannon® combines human expertise with AI-powered insights to deliver real-time, situational solutions that boost productivity and reduce unplanned downtime. Our collaboration with AUMOVIO demonstrates how intelligent shop floor assistance can transform production efficiency—through in-depth transparency, faster and more accurate troubleshooting, and better maintenance planning. By leveraging real-time data, we have been able to unlock new potential for continuous improvement."

Krushna Bhumireddy, Lead Digitalization Project Manager at AUMOVIO, adds:

"At AUMOVIO, data-driven decision-making is a core principle. DIAZI gave us the platform to bring plus10 on board with the same vision. With Shannon®, our production team can make faster and more informed decisions—and significantly reduce unplanned downtime. Thanks to AI-powered solution recommendations, we spend less time analyzing and more time taking effective action, thereby increasing efficiency and overall performance."

About AUMOVIO:

Since its spin-off in September 2025, AUMOVIO has been running the business of the former Continental Automotive division as an independent company. The technology and electronics company offers a broad portfolio for safe, exciting, connected, and autonomous mobility. This includes sensor solutions, displays, braking and comfort systems, as well as comprehensive expertise in software, architecture platforms, and assistance systems for software-defined vehicles.