ZWA at Digital Manufacturing Workshop: How the Genesis v11 System Supports Automotive Plants
We have just participated in the Digital Manufacturing Workshop at Tarczyński Arena in Wrocław. As the ZW Automation team – currently the only certified integrator in Poland within the global MEIDS (Mitsubishi Electric Iconics Digital Solutions) programme – we shared our experience in deploying advanced data analytics. We focused on specific industry challenges: integrating dispersed machine parks and building systems that, rather than merely reporting the past, enable failure prediction and genuine reduction of production costs.
Effective automotive production optimisation in practice: Genesis v11 as the heart of the ecosystem
Many of our clients face the challenge of a heterogeneous machine park, where modern systems operate side by side with legacy installations. During our presentation “Genesis: Control is trust. Data is value”, we demonstrated that automotive production optimisation does not have to involve costly replacement of the entire infrastructure. We treat the Genesis v11 system as a technological connector. With support for standards such as OPC UA, BACnet, MQTT, and SQL databases, we integrate existing assets into a single, coherent organism.
“Genesis is not just another closed technological island. It is an open solution that allows us to connect the old with the new, leveraging the potential of the machines already owned by the plant” – explained Łukasz Pozimski, Automation Engineer, during the presentation.
Case Study: From Fault Diagnosis to Predictive Maintenance
During the workshop, we presented concrete figures from our deployments. One of the most illustrative examples was the analysis of anomalies in scrap quantities across individual machine pallets. Before the implementation of reporting, locating a defective component among 40 pallets could take maintenance technicians an entire shift (8 hours). The introduction of a dedicated report reduced this process to just one hour. Across a full year, with one fault per month, this translates to a saving of 84 hours of labour – more than 10 full production shifts. This demonstrates that data-driven automotive production optimisation is the most direct path to improving the OEE indicator.
Cybersecurity and the NIS2 Standard in the Modern Plant
In an era of growing regulatory requirements – including the NIS2 directive – control over data flow has become the highest form of trust. Jarosław Szafran emphasised that the security of the Genesis v11 system is built on a Security by Design architecture.
“Precise permission management and the use of secure communication tunnels are the standard today. Importantly for many plants, the system supports operation on local servers, with no need to transmit sensitive production data to the cloud” – said Jarosław Szafran, Chief Operations Officer.
The solution we implement also offers an unlimited number of users and lifetime subscriptions, eliminating burdensome monthly fees and enabling unrestricted data access via browser or mobile devices.
Expertise, Integration and the Spirit of Sport
The workshop stood out for its relaxed atmosphere, which encouraged open knowledge exchange among engineers. The appropriate group size allowed for in-depth discussion of real challenges from the production floor. An unexpected highlight of the day was a guided tour of Tarczyński Arena and a visit to the Śląsk Wrocław Museum.
We had the opportunity to see areas not normally accessible to the public – from the players’ zone and changing rooms, through the press room, all the way to the edge of the pitch. The walk through the history of Wrocław sport at the Śląsk Museum, where modern multimedia meet legendary trophies, was a great source of inspiration. A reminder that – just as in sport – in automation, what counts is precision, strategy and a well-coordinated team.
Global Competence in the Local Market
Our presence at the workshop as speakers reflects our unique position on the map of Polish automation. ZW Automation has joined the elite group of 34 companies worldwide holding Certified status within the MEIDS programme. This confirms that our projects on the Genesis v11 platform are delivered to the highest global standards.
Why choose analytics with ZW Automation?
- Real-time transparency: See what is happening with your robots and processes here and now.
- Loss reduction: Monitoring media and raw material consumption means direct control over costs.
- Predictive Maintenance: We transform raw figures into actionable intelligence that prevents downtime.
- Fast results: First optimisation reports are ready shortly after deployment begins.
Start measuring to stop overpaying: Your automotive production optimisation
Every deployment begins with understanding the Baseline – enabling a comparison between the current state and the possibilities offered by modern technology. Only by measuring line performance parameters can we design a “tomorrow” in which production is stable and quality is predictable.
Want to find out what your data says about your costs? We invite you to get in touch and schedule a data audit at your plant. We will guide you from raw figures to concrete savings.
Genesis: Control is trust. Data is value.
