Automotive Manufacturing
Your line runs to the second. Your data should too.
UMH connects your assembly stations, press lines, and paint shops into one real-time data layer. Your production, maintenance, and quality teams get the same trusted view of every line, every shift, every plant.
Machine-level energy monitoring across stamping, paint, and body-in-white
Real-time OEE and OPE per line, not end-of-shift reports
Catena-X-ready data export, Digital Battery Passport, and IATF 16949 traceability
Siemens S7, EtherNet/IP, OPC UA, Modbus. Live in under 2 weeks
Template-based multi-plant rollout with production data flowing into SAP or your ERP
Trusted by global enterprises
The Challenge
Late data costs real margin.
A heterogeneous, plant-specific technology landscape grown organically over decades.
You can't protect margin on data you only see once a shift
Automotive assembly runs to cycle times measured in seconds, but most plants still operate on data that is hours old by the time it reaches a decision-maker. Isolated MES, ERP, and SCADA systems mean a stoppage at one station is not visible to planning until it has already cascaded down the line. Micro-stoppages under five minutes rarely get logged at all. For suppliers already operating on thin margins, the OEE points hiding in these blind spots are not a nice-to-have. They are margin. The data to recover them exists inside your PLCs and controllers, but it sits in silos that no single system can read in real time.
Downtime and energy costs are compounding against you
In JIT and JIS production, an unplanned stop does not just affect your plant. It affects your customer's plant. The cost of unplanned downtime at an automotive assembly plant runs to hundreds of thousands to millions per hour. Stamping presses, paint booths, and compressed air systems are among the largest energy consumers in any automotive plant, but most sites have no visibility into which lines or shifts are driving the bill. Energy costs have risen sharply and show no sign of returning to previous levels. Two of the largest cost lines in automotive production, and both require the same thing: real-time machine-level data that reaches the people who can act on it.
Your experienced operators are leaving, and their knowledge is leaving with them
Experienced maintenance technicians and shift leads are increasingly hard to replace, and the knowledge they carry is not documented anywhere. The operators who know that press 7 drifts after 400 cycles, or that line 3 needs extra warm-up in winter, aren't writing that down. When they leave, the knowledge leaves with them. A plant that depends on tribal expertise for uptime and quality decisions is a plant that gets harder to run every year. Real-time production data does not replace experienced people, but it captures what they know in a form the next shift can use.
Part traceability that holds up under IATF, VDA, and the EU Battery Regulation
IATF 16949 and VDA 6.3 require a complete data trail from raw component to finished vehicle. When that trail is spread across PLCs, paper logs, and disconnected quality systems, every audit becomes a reconstruction exercise. The EU Battery Regulation will require a Digital Battery Passport for every EV and industrial battery on the EU market, including carbon footprint data by manufacturing stage. Major OEMs are already mandating Catena-X registration across their supply base. Suppliers who cannot expose production data in standardised formats risk losing qualification standing.
from the floor
Case study | Böllhoff
See how industrial manufacturers use UMH to connect multi-plant operations and get real-time visibility across every site.
How Böllhoff put 20 million parts daily on a single data foundation
"We produce almost 20 million fasteners per day. That generates enormous amounts of data. Machine data, energy data, production orders. But it was all in separate systems. We had the data. We just couldn't use it."
Our Solution
One platform, every station.
Live machine data from every PLC and controller, visible across every line and plant.
Real-time OEE and quality, not end-of-shift reports
Live cycle time, takt adherence, micro-stop detection, quality gate monitoring, and scrap tracking. Calculated from machine signals, not operator entries. Production actuals flow directly into SAP or your ERP.
Machine-level energy attribution
Monitor electricity, compressed air, and thermal energy per line, including stamping presses and paint booths. Per-line attribution tells you where the cost is and where to act.
Connect PLCs and controllers in one layer
Siemens S7, EtherNet/IP, OPC UA, and Modbus, regardless of age or manufacturer, connected to one unified data layer. Robots and vision systems that expose data via OPC UA are included. No middleware, no per-connector fees.
Predictive maintenance on high-value assets
Detect drift in cycle times, pressure curves, and vibration patterns on presses, conveyors, and critical stations. Alerts fire before failures cascade. Built on the same live production data, not a separate analytics platform.
Full part traceability in seconds
Digital audit trail from raw component to finished vehicle. IATF 16949, VDA 6.3, and EU Battery Passport compliant. Available in seconds, not reconstructed over hours.
Template-based multi-plant rollout
Configuration templates replicate from plant to plant. Each subsequent site deploys faster than the last. OT-safe, outbound-only architecture under IEC 62443.
Results across automotive plants.
OEE gains, downtime reduction, and energy savings measured across connected automotive sites.
solutions
Solutions Built on UMH.
UMH is the data infrastructure. These are the outcomes it delivers.
START WITH UMH