Digitalization in industry - networking processes & increasing efficiency

What does digitalization mean in industry?

The manufacturing industry is at a turning point. A shortage of skilled workers, rising energy costs, geopolitical uncertainties and growing competitive pressure are forcing companies to fundamentally rethink their processes. Digitalization is no longer a nice-to-have - it is the decisive lever for remaining competitive.

In concrete terms, digitalization in industry means that machines, plants and systems are networked, data is recorded and evaluated in real time, processes are automated and decisions are made on the basis of valid information. Not as an end in itself, but with measurable results: lower operating costs, higher plant availability, shorter response times and the ability to develop new data-driven business models.

prodot has been supporting industrial companies on this path for over 25 years. With more than 80 IT experts, we develop IoT platforms, predictive maintenance solutions, customer portals and industrial software - from the initial idea to ongoing operation.

The status quo: potential is there - implementation is lagging behind

The figures paint a clear picture. According to a Bitkom study (2025), 71% of German industrial companies are already using Industry 4.0 applications. But a look behind the figures shows that The majority are still in the early stages.

An IFS survey of 815 managers from the manufacturing industry makes the dilemma clear:

• All respondents see technology as vital to their company's survival.

• Only 10 percent consider themselves to be digital pioneers.

• 65% are stuck in the early stages of digitalization and do not yet have a concrete plan for the next steps.

• 82% of manufacturers fear that they will no longer be competitive within three years without increased investment in new technologies.

The pressure is palpable - implementation is lagging behind. This is exactly where prodot comes in.

The most important areas of digitalization in the industry

Digitalization offers the greatest benefits where it directly intervenes in operational processes. The most important fields of application at a glance:

IoT and real-time monitoring. Machines and systems continuously supply operating data via sensors and telematics systems. Problems can be detected at an early stage - before they bring production to a standstill. Data from different sources is brought together on a central platform and analyzed in real time.

Predictive maintenance. Instead of carrying out maintenance at fixed intervals, smart systems signal the actual need for maintenance based on sensor and operating data. This reduces unplanned downtimes, extends the service life of systems and optimizes the deployment of service teams.

Digital twins. Virtual images of physical systems make it possible to simulate optimizations and changes in the production process before they are physically implemented at great expense. A decisive advantage for companies that want to become continuously more efficient.

AI-supported quality control. Quality inspection is automated. Products are inspected for defects by machines themselves and removed from the process in good time if necessary - manual inspection is no longer necessary.

ERP integration and automated data transfer. IoT data only becomes valuable when it flows back into SAP processes, maintenance orders and cost center assignments - without any manual intermediate steps. Maintenance orders, spare parts orders and alarm messages are triggered automatically.

Customer portals and data-driven services. Industrial companies that offer their customers real-time transparency about the status of their systems and devices create real added value and differentiate themselves from the competition. Digital customer portals are the interface between operators and users.

Reference: Predictive maintenance for TK Elevator

The project that prodot implemented together with TK Elevator shows what digitalization in industry looks like in concrete terms. More about the success story here.

TK Elevator operates MAX - the first cloud-based predictive maintenance solution for elevators and escalators. Real-time data from thousands of sensors in elevators worldwide is sent to the Microsoft Azure Cloud, where algorithms calculate the remaining service life of key components and predict maintenance requirements.

prodot has developed a multi-client-capable customer portal for MAX that informs MAX customers about the status of their devices at all times. The portal visualizes key figures such as operating time, door movements, distances, capacity utilization and device status in real time. Predictive maintenance warnings about impending breakdowns are displayed directly in the portal.

The results at a glance:

• Maximum elevator availability thanks to predictive maintenance instead of reactive repairs.

• Real-time transparency on the exact status of all connected devices.

• Clear usage statistics with filter functions across different time periods and device groups.

• Scalable authorization concept: users only see the devices and data for which they are authorized.

• Open REST API for integration into external systems.

"prodot's strong technological expertise with regard to the Microsoft Azure platform helps to reduce the approval processes for all project participants to a minimum and supports the rapid development of our solutions." - Christian Jung, Manager Digital Operations, TK Elevator

The prodot IoT-X Platform: from raw data to decisions

In many industrial companies, the IoT approach ends exactly where it should start: Data is created, ends up in silos and doesn't find its way into business processes. In the end, nobody makes better decisions than before.

With the IoT-X Platform, prodot has developed a solution that addresses precisely this point. The platform aggregates data from different sources - sensors, telematics systems, ERP and third-party software - in a standardized interface, makes it evaluable in real time and translates it directly into operational processes.

What the IoT-X Platform actually does:

• Manufacturer-independent connection via open standards such as OPC-UA, MQTT and REST-API - even older systems without native connectivity can be retrofitted.

• Real-time dashboards and alerts for machine statuses, operating parameters and critical events.

• Automatic SAP integration: maintenance orders, spare parts orders and machine time allocations are triggered without any manual intermediate steps.

• Scalable entry: An initial use case is sufficient as a starting point - the platform grows with the requirements.

• Available in the Microsoft Azure Marketplace with ready-to-use modules for data aggregation, reporting and process automation.

In practice, for example, the IoT-X Platform has automatically transferred telematics data from various systems to SAP for a leading road construction company - with fuel savings of up to 10 percent as a measurable result.

What investments in digitalization bring: the business case

Those who invest in digital transformation see measurable results. A PwC study on digital product development shows that companies achieve the following average improvements over five years by investing in digital technologies:

1. 19% increase in efficiency through digital product development and networked processes.

2. 17% shorter time to market thanks to faster development and approval processes

3. 13% lower production costs through automation and data-based optimization.

Particularly noteworthy: digitally leading companies achieve these results without investing a disproportionate amount in research and development. It's not the level of investment that matters - it's the strategic focus.

Why prodot is the right partner for digitalization in industry

Digitization projects in industry rarely fail because of the technology. They fail when solutions do not match the actual processes, when data silos are not broken down or when the path from raw data collection to real use is not consistently thought through to the end.

We combine IT expertise with an understanding of processes. Technical know-how alone is not enough. A good partner understands its customers' business processes and develops solutions that fit them. prodot has both - from over 25 years of project experience in the manufacturing industry.

We integrate what is already there. No industrial company starts from scratch. Existing ERP systems, established machinery and heterogeneous telematics landscapes are the starting point. We develop solutions that fit into existing structures - regardless of manufacturer and system efficiency.

We deliver transparency that is relevant to decision-making. Our solutions do not simply provide more data, but the right data - prepared for maintenance teams, production managers and company management.

We provide end-to-end support. From requirements analysis, development and integration to ongoing operation - everything from a single source. No subcontracting, no gaps in responsibility.

We build for growth. Modular architectures and open standards ensure that solutions grow in line with requirements. AI functions, new data sources or additional locations can be integrated without affecting the overall system.

Conclusion: digitalization in the industry is no longer an option

82 percent of manufacturers believe their future is at risk without digitalization - and the technologies to shape this change are available. What is needed is a clear plan, a clearly defined initial use case and a partner who will go along for the ride.

Industrial companies that act now will secure measurable benefits: lower operating costs, higher plant availability, a better basis for decision-making and the ability to build new business models based on their data. prodot is accompanying this journey - with technical depth, industry experience and the ambition to develop solutions that really work in day-to-day production.