"The configurator shows the suitable gearbox in a matter of seconds"

Interview "The configurator shows the suitable gearbox in a matter of seconds"

2023-01-30 Das Gespräch führte Sebastian Human 4 min Reading Time

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Together with IT service provider Adesso, Flender digitized all workflows for its new gearbox solution. Andreas Liesche, Managing Director at Adesso Manufacturing Industry Solutions, provides insights into the project in the interview.

Finding the right gearbox in a few seconds via an online configurator? Adesso assisted Flender in a corresponding project, as Andreas Liesche explains.(Image: Pixabay/Adesso SE) — Finding the right gearbox in a few seconds via an online configurator? Adesso assisted Flender in a corresponding project, as Andreas Liesche explains.
(Image: Pixabay/Adesso SE)

Mr. Liesche, Adesso is the digitalization partner behind Flender's newly developed gearbox, the Flender One. In this role, you supported the Bocholt-based company in automating the entire value chain for the new gearbox. How were you able to help here?

Andreas Liesche: The manufacturing industry is one of Adesso's focus sectors. Since the end of 2019, we have been the digitalization partner for Flender, and as the initial project of the digital roadmap, we support the strategically leading program 'Variant Management and Automation'. With Flender One, the first expansion stage of the new gear generation was introduced. The IT-technical implementation is based on Adesso technology and market-leading standard software.

Our collaboration has been characterized by a partnership of equals from the very beginning. Both Flender and Adesso have 25 years of expertise in complex product configuration. Our contribution included strategic and technical consulting, software development and integration, as well as the design of IT architecture and IT operations. With our broad manufacturer-neutral technology expertise, we were able to optimize existing software solutions, develop new components, and integrate them.

Let's start from the beginning. Flender wants to help its customers find the right gearbox solution faster, simplifying the product search process. How does this work?

This is where the jointly developed solution configurator comes into play: The customer simply enters the desired application, performance, and speed. Based on this, the system generates a selection of suitable configurations.

In principle, these are standard products, variants from the construction kit, or custom solutions. The customer can compare and select directly or start the detailed configuration of a customized gearbox. A complex set of rules ensures an optimal and valid configuration.

Flender's customers do not have to deal with all options and technical details. The configurator quickly shows the suitable gearbox and the necessary accessories. Of course, experts can also delve much deeper if needed.

The gearbox manufacturer itself speaks of a "breakthrough towards individualization and sustainability". Can you explain what is meant by individualization? What level of customization is possible? And where does sustainability come into play?

The new configuration solution masters closed and open solution spaces, thus offering unlimited degrees of freedom and covering all complexity classes: standard and modular products all the way to custom solutions. Flender One can accurately reflect the individual requirements of the customers.

The increased sustainability of the gearbox results from technological features such as a redesigned housing and an optimized gear set. But also, the precise dimensioning of the gearbox variants significantly contributes to this: Unnecessary over-dimensioning and resource wastage are prevented.

Probably not quite your area, but I have to ask anyway: Is there also a digital aspect within the gearbox itself? Or is all the digital focus on variant management?

The core function of the gearbox is, of course, still mechanical. However, the optional IIoT (Industrial Internet of Things) sensors transform it into what is commonly referred to as a smart product. These sensors provide plant and machine operators with a digital image of the gearbox in real use, enabling detailed condition monitoring. Operation and service can be optimized, reducing wear while maintaining consistent performance. Based on the IIoT integration, Flender can evaluate new, usage-based business models, such as 'Speed Conversion and Torque-as-a-Service'.

You describe the software solution Fire, developed as part of the collaboration, as "unique in the German manufacturing landscape." What unique features lead to this confident assessment?

The Adesso software solution Fire is an open framework for the modeling of rule knowledge, interactive variant configuration, and automation. This allows us to orchestrate processes completely end-to-end - meaning from the customer to the customer.

We integrate various configurators and rule sets under a single interface, enabling continuous automation across all IT system boundaries. This involves Best-of-Breed software based on agile methods, free data formats, and open interfaces. With Fire, we support the paradigm: Modeling, configuring, orchestrating, and automating is better than traditional rigid monoliths. We assist our customers with open integrative solutions and avoid leading them into vendor lock-in.

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Date: 08.12.2025

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On your website, you write that further products are already planned. Can you provide an outlook here?

We, at Adesso Manufacturing Industry Solutions, specialize in industry software and consulting for the manufacturing industry. In the context of the overarching themes of variant management, configuration, and automation, we focus on digitizing relevant business areas: Commerce, Engineering, Production, Aftersales. In cooperation with market-leading partner companies like SAP or Microsoft, we develop tailor-made industry solutions. We research and evaluate open integration platforms, specifically for variant manufacturers, the supply chain, smart products, and digital twins. It certainly remains exciting.