Apache Kafka in Manufacturing at Automotive Supplier Brose for Industrial IoT Use Cases

Data streaming unifies OT/IT workloads by connecting information from sensors, PLCs, robotics and other manufacturing systems at the edge with business applications and the big data analytics world in the cloud. This blog post explores how the global automotive supplier Brose deploys a hybrid industrial IoT architecture using Apache Kafka in combination with Eclipse Kura, OPC-UA, MuleSoft and SAP.

Data Streaming and Industrial IoT / Industry 4.0

Data streaming with Apache Kafka plays a critical role in Industrial IoT by enabling real-time data ingestion, processing, and analysis from various industrial devices and sensors. Kafka’s high throughput and scalability ensure that it can reliably handle and integrate massive streams of data from IoT devices into analytics platforms for valuable insights. This real-time capability enhances predictive maintenance, operational efficiency, and overall automation in industrial settings.

Here is an exemplary hybrid industrial IoT architecture with data streaming at the edge in the factory and 5G supply chain environments synchronizing in real-time with business applications and analytics / AI platforms in the cloud:

Brose – A Global Automotive Supplier

Brose is a global automotive supplier headquartered in beautiful Franconia, Bavaria, Germany. The company has a global presence with 70 locations, 25 countries, 5 continents, and about 30,000 employees.

Brose specializes in mechatronic systems for vehicle doors, seats, and electric motors. They develop and manufacture innovative products that enhance vehicle comfort, safety, and efficiency, serving major car manufacturers worldwide.

Brose’s Hybrid Architecture for Industry 4.0 with Eclipse Kura, OPC UA, Kafka, SAP and MuleSoft

Brose is an excellent example of combining data streaming using Confluent with other technologies like open source Eclipse Kura and OPC-UA for the OT and edge site, and IT infrastructure and cloud software like SAP, Splunk, SQL Server, AWS Kinesis and MuleSoft:

Here is how it works according to Sven Matuschzik, Director of IT-Platforms and Databases at Brose:

Regional Kafka on-premise clusters are embedded within the IIoT and production platform, facilitating seamless data flow from the shop floor to the business world in combination with other integration tools. This hybrid IoT streaming architecture connects machines to the IT infrastructure, mastering various technologies, and ensuring zero trust security with micro-segmentation. It manages latencies between sites and central IT, enables two-way communication between machines and the IT world, and maintains high data quality from the shop floor.

For more insights from Brose (and Siemens) about IoT and data streaming with Apache Kafka, listen to the following interactive discussion.

Interactive Discussion with Siemens and Brose about Data Streaming and IoT

Brose and Siemens discussed with me

• the practical strategies employed by Brose and Siemens to integrate data streaming in IoT for real-time data utilization.
• the challenges faced by both companies in embracing data streaming, and reveal how they overcame barriers to maximize their potential with a hybrid cloud infrastructure.
• how these enterprise architectures will be expanded, including real-time data sharing with customers, partners, and suppliers, and the potential impact of artificial intelligence (AI), including GenAI, on data streaming efforts, providing valuable insights to drive business outcomes and operational efficiency.
• the significance of event-driven architectures and data streaming for enhanced manufacturing processes to improve overall equipment effectiveness (OEE) and seamlessly integrate with existing IT systems like SAP ERP and Salesforce CRM to optimize their operations.

Here is the video recording with Stefan Baer from Siemens and Sven Matuschzik from Brose:

Data Streaming with Apache Kafka to Unify Industrial IoT Workloads from Edge to Cloud with Apache Kafka

Many manufacturers leverage data streaming powered by Apache Kafka to unify the OT/IT world from edge sites like factories to the data center or public cloud for analytics and business applications.

I wrote a lot about data streaming with Apache Kafka and Flink in Industry 4.0, Industrial IoT and OT/IT modernization. Here are a few of my favourite articles:

• The State of Data Streaming in Manufacturing
• How Michelin improves Aftermarket Sales and Customer Service with Data Streaming
• Apache Kafka for Synchronization from Smart Factory to Cloud at BMW
• Modernizing SCADA Systems and OT/IT Integration with Data Streaming at 50Hertz
• OPC UA, MQTT, and Apache Kafka – The Trinity of Data Streaming in IoT
• Apache Kafka as Data Historian – an IIoT / Industry 4.0 Real Time Data Lake

How does your IoT architecture look like? Do you already use data streaming? What are the use cases and enterprise architecture? Let’s connect on LinkedIn and discuss it! Stay informed about new blog posts by subscribing to my newsletter.