Author: AMK

In the era of Industry 4.0, data has become a crucial factor driving production efficiency across all industries, including automotive leader in the engineering and manufacturing of advanced suspension and brake systems, BWI Group leverages the power of data analytics to optimize manufacturing processes, increase efficiency and deliver quality and price optimized components to its customers.

Challenges of today’s automotive component manufacturing

Today’s automotive industry exposes manufacturers to unprecedented challenges. The growing pressure to reduce cost while maintaining the highest standards of quality and safety requires innovative approaches to production management. The ability to quickly process and analyze the massive amounts of data generated by modern production lines is key to meeting these challenges. Properly “cleaned” and processed data has the potential to be converted into decision-making processes that lead to actions, contributing to the improvement of quality, efficiency, and reliability of production lines.

Production Data Management at BWI Group

At BWI Group, we are using a data analytics system developed by the Operational Technology Engineering team, which is based on advanced tools to efficiently and reliably manage information from the manufacturing process. With our system, we achieve:

• Real-time monitoring of Production Line Performance metrics.

This includes identifying the causes of downtime, quality issues, and performance and availability losses. The OPC (Open Platform Communications) systems are used for data acquisition from machine controllers and automation equipment, providing precise and up-to-date insight into production processes. All events are automatically reported, minimizing the need for manual data entry and reducing the risk of errors. Additionally, the data for subsequent analyses is sourced from Single Point of Truth, ensuring a consistent and reliable foundation for continuous improvement and decision making processes in production environment.

• A cohesive Global Information Management Ecosystem for continuous improvement.

This includes a continuous improvement process, managing suggestions and building on lessons learned. BWI uses the Daily Management System to manage tasks and coordinate actions, allowing for effective monitoring of progress and the implementation of corrective actions. Since the environment is consistent with what is used at all levels of the organization, data flows in an organized manner without loss of information.

• An environment for converting production data into specific operational activities.

This ensures an integral and reliable flow of information. Data is processed in a hybrid model both in the cloud and using internal server capacity, improving scalability and security in information management. The solution supports the entire process from problem identification on the production line, through the implementation of corrective actions, to sharing the acquired information with other plants.

• Visualization of Key Performance Indicators (KPIs) on intuitive dashboards created in BI-class systems.

 These dashboards are optimized for different organizational roles and offer various levels of detail, enabling quick and easy analysis of key data and decision-making based on current information.

This advanced approach allows for effective production management, process optimization, and quick response to changing conditions, ultimately contributing to the increased efficiency and quality of BWI products.

Customer Centered – The Customer comes first

Improving processes through the deployment of advanced data analytics results in the single most important end outcome, which is the satisfaction of our customers.  Let’s list a few of the many benefits:

• Improving product quality by monitoring performance indicators: Quickly detect and eliminate defects, leading to lower defect rates and higher quality of final products.
  
• Increased production efficiency: Automating the data collection and analysis process helps to detect downtime and other production issues, resulting in faster delivery time and lower operating cost.
  
• Faster innovation: Data analysis enables dynamic implementation of improvements that meet market needs, and introduction of new technologies into products.
  
• Increased transparency and better communication: With data visualizations customers have a better insight into production processes and can make faster decisions based on current information.
  
• Scalability and data security: Using modern cloud technology combined with in-house server resources ensures that systems remain stable and secure even when the amount of processed data increases.

• BWI and thyssenkrupp will forge a long-term partnership to develop cutting-edge X-by-Wire chassis technology. 
• The jointly developed Electro-Mechanical-Brake (EMB) systems will enable Level-3 and above autonomous driving capabilities. 
• Start of production and global sales for the new EMB system are slated for 2026.  
• Dynamic testing of third-generation EMB prototypes has garnered significant interest from several automakers.  

April 9, Budapest. BWI Group, a world-leading tier-1 intelligent automotive chassis supplier, and thyssenkrupp Steering, a global tier-1 automotive partner for steering solutions signed a contract for the development and manufacture of a pioneering Electro-Mechanical Brake (EMB) technology. This collaboration aims to further advance Level 3 and above autonomous driving brake capabilities. 

The long-term cooperation will pave the way for further chassis-by-wire collaboration. The technical synergies will drive the future of X-by-wire chassis systems and enable the transformation from assisted to autonomous driving by enhancing safety, comfort and efficiency. 

George Chang, CEO of BWI Group, and Patrick Vith, CEO of thyssenkrupp Steering, formalized the agreement in Budapest, Hungary, on April 9. Executives from both companies were present at the signing ceremony. 

“We at BWI are excited about the future of chassis-by-wire,” said George Chang, CEO of BWI Group. “We are pleased to be collaborating with thyssenkrupp Steering on this truly innovative technology, leveraging our expertise in braking systems since 1934 and our century-long heritage of chassis technology innovation to drive progress within the industry.”
 

“Together, we want to contribute to the next generation of chassis systems and set standards for safety, performance, and sustainability” said Patrick Vith, CEO of thyssenkrupp Steering. “Our many years of experience as a major supplier in the steering sector will stand us in good stead.” 

Under the agreement, BWI Group and thyssenkrupp Steering will leverage their strengths and expertise in safety-critical systems and software to bolster their collaboration.  Both companies will accelerate the joint development of EMB systems as one important element of future vehicle motion control (VMC) solutions.  

BWI Group brings more than a century of history and real-world R&D and production experience to the development of the new EMB product, including expertise in brakes and suspension systems. It serves more than 50 customers worldwide. The company also leverages its prior experience with EMB systems as Delphi in the 2000s.  

thyssenkrupp Steering has been developing steer-by-wire technology for many years. The company contributes deep knowledge of new electrical/electronic (E/E) architectures and software, as well as its competence in electro-mechanical braking systems derived from steering technology. 

Dr. Karsten Kroos, CEO of thyssenkrupp Automotive Technology said “Through partnerships like this one, we aim to develop competitive components for modern chassis systems serving the global automotive industry in an agile, innovative, and capital-efficient manner. Our focus is on synergies in technology and costs.” 

Dr. Karsten Kroos, CEO of thyssenkrupp Automotive Technology said:

“Through partnerships like this one, we aim to develop competitive components for modern chassis systems serving the global automotive industry in an agile, innovative, and capital-efficient manner. Our focus is on synergies in technology and costs.” 

Doug Carson, CTO of BWI Group said: “We have strong expectations in forging this strategic partnership with thyssenkrupp. Together, our brake-by-wire expertise will drive chassis technology breakthroughs that meet global standards and promote EMB adoption in Europe, North America, and Asia.”    

EMB R&D will occur at BWI Group’s global R&D Centers located in Italy, Poland, U.S. and China, along with its Shanghai Software Center; thyssenkrupp’s technical centers in Hungary and Liechtenstein will also perform significant roles. 

Pioneering full-dry EMB technology 

The jointly developed EMB system is a premier offering that complements both companies’ controlled chassis portfolios. The two companies are now developing the third generation of EMB, a revolutionary technology that fulfills the need for simplified vehicle assembly while providing braking redundancy for Level 3 and above autonomous driving technologies. 

Featuring a dual-motor design, efficient packaging, and novel redundancy, the newly developed EMB caliper ensures safety and reliability. Its reaction speed for time to wheel lock (TTL) is nearly twice as fast than modern one box wet brake systems.  Additionally, it enables complete braking energy recovery and fully meets the electric and intelligent needs of braking systems for smart vehicles. 

EMB is a visionary brake technology that eliminates the need for brake fluid while offering precise control with zero drag. It will become the definitive solution for future brake-by-wire technology, replacing current hydraulic calipers, and the accompanying One-Box and Two-Box brake actuation/modulation systems.  

Globalized production anticipated in 2026 

Looking ahead, the project plans to establish state-of-the-art automated production lines by 2025. Production and product delivery are expected to begin in 2026. BWI Group’s advanced automated production facilities worldwide will coordinate and expedite the mass production of EMB systems, ensuring this groundbreaking technology is available to a wide array of automakers worldwide.  

Leveraging BWI Group’s nine manufacturing facilities and multiple proving grounds spread across key automotive centers in Asia, Europe, and North America, this cooperation regarding EMB systems, ensures efficient production and widespread distribution. Because the products are designed for worldwide markets, they will be manufactured to high standards to fulfill the variety of local demands and requirements.  

Strong market growth ahead 

EMB technology is becoming the focus of key automotive manufacturers, and it represents game-changing evolution for automotive chassis systems and the future demands of propulsion drive systems, electrification, performance, and sustainability. The jointly developed EMB caliper system underwent dynamic tests in Sweden, U.S. and China. Enthusiastic feedback and interests well as cooperation intentions were secured with major automakers in the three continents. 

An industrial forecast projects that EMB calipers will contribute 13% of the total global braking market by 2035. 

EMB dynamic test leads brake-by-wire

BWI Group conducted dynamic extreme-cold tests for the quality and performance of the product lineup installed on all-new mainstream car models in Europe, North America and Asia, while its revolutionary Electro Mechanic Braking technology dynamic test wrapped up on Mar 8.

As the world’s leading tier one supplier, BWI Group insists on carrying out winter tests in three continents, which not only proves the performance and working status of the Group’s intelligent chassis products in real snow and cold conditions, but also reflects the more stringent global R&D standards of BWI Group.

George Chang, member of Board of Directors and Global CEO of BWI Group said, “Our products are sold globally alongside vehicle products from over 50 customers worldwide. Consequently, BWI Group must adhere to increasingly rigorous international technical standards throughout the entire R&D to production process. For instance, we firmly maintain conducting extreme cold tests annually in China, the United States, and Europe to fulfill the demands of international standards.”

Given the global chassis market is rife with varying regulations and technical standards in areas such as safety, environmental protection, noise, and electromagnetic compatibility, the smart chassis company works in world-class vehicle testing centers in Swedish Lapland, the U.S. Michigan’s Upper Peninsula and farthest northern Heilongjiang Province in China every winter to prove the latest smart brakes and suspensions for world-renowned auto brands’ latest models.

Based on the customer centered culture and values, the international premium tier-1 supplier’s winter tests in three regions are designed to focus on real ice, snow, and cold conditions for robust product development to meet the strict standards and differentiated needs of the three major automobile markets, drawing closer to Customers in Europe, the U.S., and China.

This year, the company’s line-up in the global winter tests include iDBC1 (1-Box) integrated brake control system, Electric Parking Brake, Electric Stability Control, the 4^th generation MagneRide suspension, and the Semi-Active Roll Control system.

It is worth mentioning that the company’s industry-leading controlled braking technology, full-dry Electro-Mechanical Brake, is now undergoing a dynamic extreme-cold test on a premium SUV in Arjeplog, Sweden, to prove its performance and global quality.

The full-dry EMB is full electric plug and play product fully meeting the needs of smart braking system to empower higher-level autonomous driving, and it quietly completed its maiden winter test in February, 2023 in China’s Heilongjiang Province.

Ambitious future target

Facing the future of intelligent and electric automobiles, BWI Group has actively developed technology and expanded production of smart chassis products with the efforts of over 900 R&D team members worldwide.

BWI Group’s brake-by-wire and active suspension products are empowering Level-2 to Level-4 Plus autonomous driving and lead to a climbing market share of intelligent products in global sales.

BWI Group’s brake-by-wire products recently entered the European market in a large deal with a well-known European auto group, and also returned to the mainstream market in North America with a high-volume application last year.

The company started providing iDBC2 (2-Box) and iDBC1 intelligent wired braking systems in the second half of 2023. An iDBC1 production line recently completed its construction in Jiangsu province, China.

George Chang said, “Our smart chassis products, including wired braking and active suspension systems, are gaining global markets speedily, and their order values are 1.7 times of our foundation brakes and passive dampers last year.”

BWI Group’s braking and suspension products lead the market with high quality in the same field and have been recognized by more than 50 global automakers. Thanks to the progress on technological breakthroughs, business development, and production, The company’s total order value rocketed by nearly 300% year-on-year in 2023.

The company’s solid development has benefited from the integration of its global resources from three continents, Asia, Europe and North America, to empower global smart mobility.

With a heritage reaching back over 100 years, BWI Group is now operating a total of 9 production bases, 7 research and development centers, and 1 software center worldwide.