At AKA Automotiv, technology and research are fundamental pillars of our long-term competitiveness. By embracing Industry 4.0 principles, IoT technologies, and advanced manufacturing systems, we continuously improve operational efficiency, quality, safety, and sustainability across our production facilities.
Our digital transformation strategy is built on real-time data acquisition, intelligent analysis, and seamless integration between equipment, systems, and people.
Industry 4.0 & Industrial IoT Applications
The Internet of Things (IoT) enables everyday objects and industrial assets to communicate, exchange data, and operate in a synchronized manner. In an industrial context, Industrial IoT (IIoT) connects machines, sensors, and advanced analytics platforms to generate actionable insights from production and environmental data.
Historically, many of our manufacturing systems—robotic cells, presses, cataphoresis plants, and assembly lines—operated through predefined sequences and safety rules. With the integration of IoT applications, we have expanded these capabilities by collecting data not only from core production equipment, but also from auxiliary systems and the working environment.
This holistic data approach allows us to monitor, control, and optimize equipment parameters dynamically, adapting operations to environmental and process conditions in real time.
Digital Factory Ecosystem
At AKA Automotiv, we continuously collect and utilize data to create efficient, safe, and sustainable working conditions. Through a wide range of digital applications and platforms, we monitor multiple operational domains and integrate insights directly into our processes.
Our digital ecosystem includes, among others:
- AKA Web Portal Applications
- Occupational Health & Safety Risk Data Collection and Analysis Program (Intenseye)
- Rework Asset Tracking Software
- AI-Based Visual Defect Detection Systems
- AKA Communication Center (AIMER)
- CSL Control Software
- Digital Subcontractor and Visitor Management System (Wellcome)
- SCADA-Based Compressed Air Monitoring System
- Cooling Water Monitoring and Management Systems
- Process Gas SCADA Monitoring Systems
- Online Wastewater Analysis Systems
- Hydraulic Oil Monitoring Systems
- Radiant Heater Tracking Systems
- Natural Gas Consumption Monitoring Systems
- Online Energy Monitoring Platforms
- Laminated Sheet Loading Algorithms
- Lone Worker Alert Systems
- Forklift Warning Systems
- AI-Based Truck Loading Zone Warning Systems
- Controlled Access Zone Warning Systems
- Fire Monitoring and Alarm Visualization Systems
- Digital Carbon Footprint and ISO 50001 Energy Management Platforms
Through these integrated systems, we confidently advance toward a paperless and digitally driven factory environment.
Manufacturing Execution System (MES)
To reduce human-centered production dependencies and increase accuracy, AKA Automotiv has integrated Manufacturing Execution Systems (MES) into its production and assembly lines.
MES serves as a fully integrated platform that manages production operations between shop-floor equipment and ERP systems. By digitalizing production workflows, we ensure continuous, accurate, and real-time data collection, analysis, and execution.
Key capabilities include:
- Real-time monitoring of production parameters via sensors, tablets, kiosks, and barcode readers
- Digital work orders and operator instructions integrated with ERP
- Full traceability of production and quality processes
- Automated scrap and rework tracking
- Digital quality checkpoints at batch start-ups and shift changes
- Early warning alarms before control limits are exceeded
The selected MES solution (Siemens Opcenter) is fully integrated with our internally developed Automotive Traceability Portal and CSL Recording & Tracking Systems, enabling end-to-end traceability throughout the entire production lifecycle.
Production orders are automatically received from ERP systems, eliminating manual prioritization. All production, quality, maintenance, and fault notification processes are digitally recorded, enabling real-time and historical OEE reporting across Availability, Performance, and Quality metrics.
Quality & Maintenance Digitalization
Quality personnel can digitally report nonconformities directly through the MES system. Product quality data is monitored in parallel with production, and automatic alarms are transmitted to Quality teams, ensuring full process traceability.
Maintenance processes are accelerated through automatic fault notifications sent to the Maintenance Department via ERP integration. Real-time PLC data monitoring enables advanced root cause analysis using historical data, significantly improving response times and reliability.
Logistics operations are also optimized, as component supply and container replenishment requirements are automatically transmitted to logistics operators’ tablets, minimizing waiting times and manual coordination.
SIRI – Smart Industry Readiness Index
AKA Automotiv actively measures and improves its digital maturity through the Smart Industry Readiness Index (SIRI) program.
SIRI is the only digital maturity assessment methodology officially recognized by the World Economic Forum (WEF). Developed by McKinsey, Siemens, SAP, and TÜV SÜD, SIRI provides a globally standardized framework for evaluating and benchmarking digital transformation readiness.
The framework applies to organizations of all sizes and industries, from family-owned businesses to multinational corporations.
AKA Automotiv joined the SIRI audit program to assess its Industry 4.0 readiness, identify improvement areas, and accelerate its digital transformation journey. Based on audit results, continuous improvements have been implemented—particularly in horizontal and vertical system integration.
Completed and ongoing digital transformation initiatives include:
- Budget and Cash Flow Management
- Integrated Human Resources Management
- Manufacturing Execution Systems (MES)
- Product Lifecycle Management (PLM)
Our digital transformation journey is continuous, driven by structured assessment, measurable improvement, and long-term strategic vision.
