Sustainability How Lasers Remain Operational Longer

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TRUMPF Laser- und Systemtechnik SE

FAULHABER Drive Systems

Brose Vehicle Parts and Trumpf jointly developed the health check for lasers—a service that makes the reuse of lasers not only sustainable but also safe.

When Oliver Meusel talks about lasers, it quickly becomes clear: here is someone who knows both theory and practice. He has been working at Brose Fahrzeugteile for over 30 years and today serves as an expert in welding technology. In his team, he develops technologies, designs processes, and validates products. And because Meusel knows what matters in manufacturing, he often has suggestions for products and services that make everyday life easier for customers. His ideas typically arise directly from the practical challenges he has to overcome.

And it was the same with the Health Check for lasers. "At Brose, we always evaluate during product development: Do we need to purchase a new system for this? Or can an existing machine be reused?" Meusel explains and elaborates: "Especially with lasers, the latter is attractive: no new investment, the system has already been depreciated, and it’s also sustainable." But: Who can truly say whether a laser is still fit enough for a new project after years of use?

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An Idea Becomes A Product

A question he posed to his partners at Trumpf. How about developing a thorough check that provides decision-makers with a transparent, objective, and comprehensible overall assessment of the system—like a kind of used car appraisal? By combining the analysis of existing laser data with an in-depth on-site inspection by a service technician, all the advantages and disadvantages of a new purchase versus reuse could be evaluated. What does each decision specifically mean in terms of costs, risks, and sustainability? The experts at Trumpf quickly recognized the benefits such an assessment could offer customers and, together with Oliver Meusel, developed a Health Check for lasers. Meusel coordinated internal needs, brought together colleagues from different plants, gathered feedback—and Trumpf listened.

Condition Monitoring: How Are You Today, Dear Laser?

The analysis of laser data is a given at Brose. For years, the company has relied on condition monitoring from TRUMPF. All lasers deployed worldwide—over 200 units—are connected to the system. It proactively monitors irregularities and faulty states using algorithms and Trumpf service experts, thereby preventing downtimes. "I consider condition monitoring a powerful tool and recommend it to each of our plants," says Meusel. However, for deciding whether a used laser can be integrated into a new project, that’s not enough for him. Condition monitoring shows the current state—the Health Check is designed to also look into the past and provide a forecast for the future.

Health Check: Dear Laser, How Have You Been So Far?

The Health Check for lasers takes additional questions into account: What was the condition of the device during its previous operating period? How often were repairs and maintenance performed? What is the status of service and spare part availability? Is an overhaul worthwhile, and is there an option to upgrade the system with smart services, such as Trumpf's automated quality data retention "Quality Data Storage" or independent monitoring with Smart View? These are questions that matter not only to decision-makers in Coburg but also across Brose's 68 locations worldwide.

Planning Reliability Instead of Surprises

In the meantime, the service for which Brose was the pilot customer is now in use. Meusel recommends that all his colleagues in EU plants include the check for every new use case for lasers. A global rollout is already being considered. "The colleagues from the plants are very satisfied. The Health Check provides assurance and offers a solid decision-making basis for everyone involved during plant relocations," Meusel summarizes. And even though the added value of the service cannot truly be expressed in euros and cents, he states: "I see the Health Check as insurance: we avoid project delays, keep an eye on wear part costs, understand spare part availability—
and simply know what we’re dealing with when continuing to use a functional but 'aging' laser." With this approach, Brose also contributes to the company’s sustainability goals: "Instead of automatically purchasing a new device, we now assess what the existing laser can still achieve—including its energy consumption and CO₂ footprint." He particularly highlights the collaboration with Trumpf during the development of the Health Check: "The exchange is always professional, open, and solution-oriented—even when things get contentious." Meusel would recommend the service to anyone responsible for production systems: "It helps with decision-making and ensures that goals—whether economic or ecological—can be reliably and securely achieved."

*Corporate Communications Officer, Trumpf

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