Bosch Security and Safety Systems I Japan
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Integrated solutions to deliver Security, improve operational efficiency and reduce accidents at the manufacturing industry

When it comes to productivity a factory demands smooth processes without interruptions. Threats like fire, accidents, sabotage and espionage need to be prevented in a smart way without effecting the running business. Also, in order to reduce costs it is necessary to increase efficiency as much as possible.

Safety first

Keep the premises, machinery and workers safe with the most reliable solutions

Improve security

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Increase efficiency by using security products ‘beyond security’

Bosch security solutions for industrial manufacturing

Unauthorized access of people and vehicles

Unauthorized access of people and vehicles

Unauthorized access of people and vehicles

It is very important for production plants to maintain control over who is allowed to access the premises. The easily scalable Bosch Access Control solutions offer a combination of cutting-edge technology, open access and strict security. Our portfolio includes all access control components from different software options and controllers to a wide range of readers and credentials as well as biometric solutions to meet strict security requirements and to ensure maximum protection against unauthorized intruders. Violations automatically trigger an alarm in the software so immediate action can be taken to deal with the situation. The system monitors and records any unauthorized access attempts. Together with video surveillance, this makes it possible to capture and record all access events. Our access control solutions can grow according to your security needs, because of the scalability of the components.

Unauthorized access of people and vehicles
Intruder at the perimeter area

Intruder at the perimeter area

Intruder at the perimeter area

Manufacturing companies are vulnerable to theft, espionage and sabotage. To prevent incidents from happening it is important to protect the premises with automated perimeter protection. Bosch offers powerful tools for fast intervention, to detect, assess and respond quickly to objects approaching the perimeter area. IP cameras with robust built-in Video Analytics detect persons, cars or objects left behind 24/7 and are resilient to false alarms. Suspects can be detected in video footage, even when hiding in dark areas. Built-in infrared illuminators make objects visible up to 550 meters away, and thermal images allow detection of suspects hiding, for example, in bushes. When an intruder passes the perimeter zone, cameras automatically follow them to support intervention. Real time feedback is provided about the breach location and activities taking place. The security operators are able to view the situation in real time. Multiple objects can also be displayed on a map, showing their location, size, and speed to enable quick intervention. This reduces the number of false alarm signals operators must deal with.

Intruder at the perimeter area
Inventory losses due to theft

Inventory losses due to theft

Inventory losses due to theft

When it is noticed that there is inventory missing, it is necessary to create an extra layer of security to check what happened. Connecting BVMS – the video management from Bosch - with local warehouse management software and using the cameras with built-in Video Analytics, it is possible to detect goods movements within the shelve area, automatically cross-check incidents with scheduled tasks of the warehouse management software. Shipments without a related picking order create an alarm event to prevent theft. Whereas the logistics team previously required several hours to manually locate a lost item, every item now receives a tracking number connected to video recordings documenting its movements. This level of transparency allows the logistics team to solve inventory problems within minutes, instead of hours.

Inventory losses due to theft

Bosch safety solutions for industrial manufacturing

Fire at manufacturing sites

Fire at manufacturing sites

Fire at manufacturing sites

Detecting flames and smoke in harsh environments like dusty industries is very important for production plants. The consequences of a fire outbreak could be devastating for your business. Bosch offers a fully modular fire system adapted for manufacturing sites, that can grow according to your needs. Our fire detection systems help to prevent loss of life, loss of inventory and stock, and business continuity disruptions. The characteristics of production halls; high ceilings, dusty or humid areas or even with explosive materials involved, prove to be difficult to reliably protect against fire. Bosch has specific solutions for these circumstances, like very reliable detectors that take the environment in account, certified silicon free devices suitable for clean room or lacquering areas, detection solutions designed for areas with high ceilings, signaling devices suitable for environments with a lot of noise and smoke detectors for explosive areas with low grade risk. Bosch also offers video-based fire detection, where cameras use intelligent algorithms to identify smoke and flames at the earliest stage. If an indication of fire or smoke is detected, an alarm is immediately triggered, and the location is pinpointed in the control room. This provides time-critical information that can prevent damage to production or stock through fire or unnecessary activation of a sprinkler head.

Fire at manufacturing sites
Forklift / AGV accidents

Forklift / AGV accidents

Forklift / AGV accidents

As one of the most commonly used tools in plant logistics’ activities, forklifts/AGVs are playing an increasingly important role in the manufacturing process. Once an accident occurs, it will cause production interruption and even casualties could be produced.

The best way to prevent accidents is to make sure that no one enters the working area of the forklift/AGV while it is working. With built-in Video Analytics, Bosch cameras can smartly differentiate between a person and a forklift/AGV, and instantly create an alarm if anyone steps into the forklift/AGV area when it is moving. Meanwhile, workers can actively be warned when forklifts/AGVs come too close. By adding specific script rules, cameras can intelligently know under what kind of circumstances they do not need to alarm, even with people around. For instance when the vehicle has to stop for unloading or a status check.

Of course, it is also necessary to raise the safety awareness of drivers. Cameras with built-in video analytics can define paths that forklifts/AGVs need to follow. Non-rule-obeying forklift drivers can be identified and asked to follow additional safety training. Based on the camera footage, accidents can be investigated and analyzed, with the improvement of routes and rules as a result.

Forklift / AGV accidents
Workers neglect wearing safety vests

Workers neglect wearing safety vests

Workers neglect wearing safety vests

The use of safety vests by people that work in potentially hazardous areas makes them easily visible, in order to prevent injuries and accidents. To manage safety protocol at the site and making sure that all of the employees are following the protocols on wearing safety vests, surveillance cameras can be used to enforce the safety rules. Using our cameras with built-in Video Analytics, it is possible to differentiate whether a person is wearing a safety vest or not. If not, the verification done by the camera allows the Access Control System to give access only to workers wearing a safety vest. This way non-rule-obeying workers can be identified and receive additional safety training. In case of an audit, this solution can proof that the company is managing the safety protocol.

Workers neglect wearing safety vests

Bosch operational solutions for industrial manufacturing

Manage access rights for several sites

Manage access rights for several sites

Manage access rights for several sites

Manufacturing companies that operate in different countries or even continents, could benefit from a solution to control access rights for several sites in an efficient and transparent way. With the Access Engine of our Building Integration System (BIS), Bosch offers you a global access solution for multiple offices and manufacturing sites, in a centralized management system with one central database. This allows employees who visit different sites to easily enter the building with a standardized ID card, that can provide access to all sites. This way it saves the company time and money, because it is no longer needed to apply for a temporary access card each time, going through all the additional security procedures. Also, 3rd party software can be used to tailor specific solutions according to your wishes. The global presence of Bosch ensures that everywhere in the world you can get support for setting up your local sites. Furthermore, our solutions are perfectly scalable for future expansion of your business.

Manage access rights for several sites
Missing goods in the inventory

Missing goods in the inventory

Missing goods in the inventory

With the Internet of Things (IoT) and a customized integration between video analytics and warehouse management software it is possible to create a solution to detect inventory theft and track missing shipments.

Bosch cameras with Intelligent Video Analytics process image data in real time and detect suspicious activities using an algorithm. Using their built-in Camera Trainer, Bosch cameras can be taught to recognize objects in the warehouse such as forklifts and shipment items. Once the security system learns to identify these objects, it is ready to interface with the center’s logistics system.

The next step is to create a direct interface between the warehouse management system and BVMS – the video management system from Bosch. Creating the connection adds a new level of intelligence to the center’s video surveillance: the smart cameras now act as IoT sensors, that can identify products stored in the warehouse management system software. The system automatically cross-checks security incidents with scheduled tasks in the warehouse system. Thanks to this ‘smart’ automation, operators only receive an alarm when a worker enters an aisle without a task – and no alarm is triggered if the worker passes through without stopping.

From an operations perspective, this Industry 4.0 solution not only boosts security but also answers the center’s need to replace the time-consuming manual tracking process for misplaced items and shipments.

Missing goods in the inventory
Boxes piling up on a conveyer belt

Boxes piling up on a conveyer belt

Boxes piling up on a conveyer belt

As an important part of modern production and logistics, a smooth conveyor belt transportation symbolizes the smooth operation of the entire production line and/or logistics transportation process. An accumulation of products on the conveyer belt means that somewhere in the production or logistics chain something goes wrong. If not handled in time, it may eventually lead to the interruption or even paralysis of the entire production line or logistics’ process. Bosch intelligent cameras with Camera Trainer can be trained to give an occupancy alarm if there are too many boxes, so that operators can be informed timely to check, ensuring not to distort production or logistics. Moreover, Bosch cameras can generate business intelligence with structured video data by monitoring the conveyer belt, which is helpful to optimize production and logistics.

Boxes piling up on a conveyer belt
Tracking incoming materials waiting for inspection

Tracking incoming materials waiting for inspection

Tracking incoming materials waiting for inspection

Production plants have a great demand for raw materials, which are usually supplied by different vendors. Therefore, the IQC (incoming quality control) of these materials has always been tricky. When the quality control operator needs to check the materials by random samples, it is often very difficult for them to find out the target due to excessive incoming materials and chaotic piling up. A great deal of time and manpower are hence wasted.

Using their built-in Camera Trainer, Bosch cameras can quickly locate the incoming materials that need to be inspected amongst huge quantities of materials, by learning how to read different vendors’ tags. This greatly shortens the inspection time of the IQC operator and improves highly the efficiency for the production.

Tracking incoming materials waiting for inspection
Keeping supply monitored & replenished

Keeping supply monitored & replenished

Keeping supply monitored & replenished

A smooth production is depending on the constant availability of assembly materials. When the materials are put on shelves or racks, operators constantly need to check whether the stock needs to be replenished. Relying on such an incidental inspection could lead to delayed replenishment or even supplies being out of stock. This leads to low production efficiency as well as valuable time of personnel being used.

Using their built-in Camera Trainer, Bosch cameras can inform you about the status of your supplies. They can for instance detect that material boxes on a shelve are empty and also they can be trained to know what is in each specific box. They can notify operators in time about the materials out of stock and which materials need to be replenished. Moreover, by connecting with BVMS - the video management system from Bosch -, the inventory can be vividly visualized in real time. This ‘virtual inventory’ can significantly reduce costs, shorten the replenishment lead time, and ensure a smooth production.

Keeping supply monitored & replenished
Sound distribution in large halls

Sound distribution in large halls

Sound distribution in large halls

Production halls are environments with loud ambient noise, in which unclear announcements confuse workers or are simply not heard. In case of evacuation it is crucial that everybody knows what to do, so being able to offer a good distribution of sound, even in big spaces with high ceilings like production halls, is crucial. Next to this important element of safety, being able to listen to music while doing production work, significantly improves the working conditions of workers in many cases. Bosch has an extensive loudspeaker portfolio, with flexible Public Address (PA) solutions that can increase/decrease sound levels in environments with loud/low ambient noise, provide control over a small and very specific area or can also address the full production plant if necessary. Especially suitable for large areas and high-ceiling applications like production halls is the powerful Hemi-directional loudspeaker. Because of the exceptionally large area this loudspeaker can cover, only very few are needed in large halls, making it a very cost effective solution.

Sound distribution in large halls

Overview of our industrial manufacturing solutions:

Overview of our industrial manufacturing solutions

A global industrial manufacturing security and safety partner

A global industrial manufacturing security and safety partner
Mohn Media needed a solution that would enable early detection of fire hazards hazards in its waste paper processing facilities. Bosch technology proved to be able to function reliably despite the high levels of dust generated on site.
Mohn Media Mohndruck in Gütersloh, Germany. Mohn Media is Europe’s leading print service provider. The company was looking for a solution that would enable early detection of fire hazards in its waste paper processing facilities. The technology needed to function reliably despite the high levels of dust generated on site. There was also a requirement for the fire protection and security systems to be easily integrated into a single comprehensive management system.
Bosch and Sirio Group cooperated to fulfill the security demands from dairy food producer Granarolo in Italy. The highest protection of the perimeter is guaranteed by creating non-crossing rules througout the company perimeter.
Granarolo S.p.A in Italy. The complexity of the project was mainly due to the large area of intervention. Non-crossing rules have been created throughout the company perimeter: the rules generate real time alarms on various internal client workstations, some of which are manned 24/7, thus guaranteeing the highest protection of the perimeter. Thanks to the cooperation between Bosch and Sirio Group, the final solution has met the customer expectations. (2018)
To reduce the risk of fire, Bosch AVIOTEC solution keeps under control the production line and the warehouse of Richetti SpA, an Italian food industry specialized in the production of chilled and frozen snacks.
Richetti Food Industry in Italy. Richetti SpA is an Italian food industry specialized in the production of chilled and frozen snacks. The installed Bosch solution includes cameras for perimeter monitoring and indoor surveillance. In order to reduce the risk of fire, Bosch AVIOTEC solution keeps under control the production line and the warehouse. (2017)
Bosch’s AVIOTEC video-based fire detection system was installed at two halls of KME Mansfeld, one of the world’s largest copper manufacturers. The intelligent algorithms ensure early detection of smoke and flames, offering a reliable protection to KME’s factories and employees.
KME Mansfeld in Hettstedt, Germany. KME is one of the world’s largest manufacturers of copper and copper alloy products. The company faced the challenge that conventional fire alarm systems are often not enough to protect large factory halls used for metalworking operations, employees and equipment. High ceilings, greater fire hazards and interference from reflected light characterize these halls. In two of the halls at the Hettstedt site in Saxony-Anhalt, our AVIOTEC video-based fire detection system was installed. Intelligent algorithms integrated in the camera ensure reliable early detection of smoke and flames, enabling the factory to use targeted, appropriate action to extinguish the fire before it can spread.
Mouka Limited, Nigeria’s foremost supplier of branded mattresses and foam-based products needed a system that can detect fire and smoke in less than 30 seconds. Bosch had the solution with their unrivalled video-based fire detection.
Mouka manufacturing company Lagos, Nigeria. Mouka Limited is Nigeria’s foremost supplier of branded mattresses and foam-based products for sleep solutions with over 800 employees at three factories across the country. Due to using high flammable materials the manufacturing company required a system that can detect fire and smoke in less than 30 seconds.
It was important to ensure safety of BSH facilities in Poland. Each location of the factory had different environmental conditions and requirements. Bosch had the right solutions to equip the plants with appropriate security and safety systems.
BSH facilities in Poland. Within the development of BSH activities, it was important to ensure the safety of employees and facilities, which - taking into account the specifics of the industrial sector -required an individual approach by Bosch Building Technologies. Each location in Łódź, Wrocław and Rzeszów had different environmental conditions and requirements. Large volume of buildings, overhead cranes used in the production process, humidity, dust – these are some of many specific factors that had to be taken into account when equipping plants with security and safety systems. (2019)
Crocus Nano Electronics had the aim of creating world’s first plant that specializes in the production of devices based on MLU. They needed a ultra-modern and reliable fire alarm system, which Bosch could provide.
Crocus Nano Electronics in Moscow, Russia. Crocus Nano Electronics is a joint project of RUSNANO and Crocus with the aim of creating the world's first plant that will specialize in the production of devices based on MLU (Magnetic Logic UnitTM) on 300mm wafers using Thermally Assisted Switching™ technology. The customer was faced with the task of acquiring a modern and reliable fire alarm system. (2015)
A new plant for the production of the Italian company Ferrero covered a huge area of 80.000 m². The highly sensitive industrial premises are now protected using Bosch solutions, preventing unauthorized access and detecting suspicious behavior 24/7.
ZAO Ferrero Russia Vorsha Sobinskoye, Russia. A new plant for the production of confectionary of the Italian company Ferrero was built in the village Vorsha Sobinskoye, in the Vladimir region. It is the first Ferrero plant in Russia and the second in Eastern Europe. The huge area of the plant covers 80.000 m² with 37.000 pallet-places. One of the main challenges that Ferrero faced was to secure the highly sensitive industrial premises from unauthorized access and to detect suspicious behavior 24 hours a day. (2012)
On the territory of the Mercedes-Benz Manufacuring RUS , 7 infrastructural buildings are located covering the area of 85 hectares. All the buildings are equipped with the security and safety products of Bosch.
Mercedes-Benz Manufacturing RUS in Esipovo, Russia. Mercedes-Benz Manufacturing RUS is a Mercedes-Benz premium passenger car manufacturer in Russia. In 2019, a work on equipping and commissioning a new Mercedes-Benz passenger car factory in Moscow Region, Esipovo Industrial Park was completed. On the territory of the plant 7 infrastructural buildings are located covering the area of 85 hectares - all of them are equipped with the products of Bosch Security and Safety Systems. (2019)
Naksan Holding operates three factories in Turkey. It required video surveillance solutions for all factories but wanted to centrally manage them. Bosch made sure that the perimeter was ensured and entry and exit points were monitored.
Naksan Holding Gaziantep, Turkey. Bosch Security Systems has delivered a centrally managed video surveillance solution for three production plants of Naksan Holding. Through its subsidiaries, Naksan Holding manufactures and markets plastic packaging products, fabrics, and carpets. The company operates three factories in Gaziantep, Turkey, close to the Syrian border. For security reasons, it required video surveillance solutions for all three plants but wanted to centrally manage them to benefit from efficient operations. The primary goals were to ensure perimeter security and to monitor entry and exit points for people and vehicles as well as production areas. (2014)
At the production plant of Türk Traktör Erenler Factory, the Bosch fire detection system works together with the Bosch Voice Evacuation System to ensure a safe and secure evacuation.
Türk Traktör Erenler Factory in Erenler, Turkey. The 290.723 m² area of the factory is used to manufacture 50.000 tractors, in a high quality and modern technology. The Bosch Fire detection system responds to the needs of different application areas of the factory and works together with the Bosch Voice Evacuation System to ensure a safe and secure evacuation. (2015)

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Our contact persons

Juergen Alz

Juergen Alz

Global Vertical Manager, Manufacturing Expert

Juergen Alz

Global Vertical Manager, Manufacturing Expert

“For me, Industry 4.0 means the ability to connect Bosch products with complimentary systems in the Industrial environment. Therefore improving security, safety with the efficiency of processes”

Our expertise comes with experience from more than 1600 Industrial installations worldwide, also from our own 245 manufacturing sites. Hence, believe we are well positioned to share real life experience, the challenges, along with best practice. My network into Bosch divisions such as Rexroth, Bosch Connected Industry allows me to provide holistic solutions beyond a classic security system.

To discuss your requirements, connect with me through mail or LinkedIn.

Juergen Alz
Zhongxi Huang

Zhongxi Huang

System application, Manufacturing Expert
China

Zhongxi Huang

System application, Manufacturing Expert

China

"By understanding the actual needs of the plant via on-site consulting, we have a clearer knowledge of the production process, how different departments works together, division of labor etc., which also inspires us with more ideas for our solutions. At the same time, we can verify our products through the project, thus providing customers with better and more customized solutions"

I focus more on how to reduce cost and resource consumption and improve operational efficiency in all aspects with intelligent and integrated solution according to customers’ request. With almost 15 years’ experience in access control systems and integrated platform establishment, I have a more comprehensive understanding of the industry. Hope that I can use my expertise to create future-oriented production models for customers.

If you want to discuss solutions that fit your company needs, connect with me through mail.

Zhongxi Huang
Robson Marzochi

Robson Marzochi

New Business Developer, Manufacturing Expert
Latin America

Robson Marzochi

New Business Developer, Manufacturing Expert

Latin America

“The security system that was previously used for monitoring, today works as intelligent sensor that goes beyond security”

Technological evolution is a constant in all markets, security has gone even further. Devices with artificial intelligence now bring information to support in the continuous improvement of processes efficiently. With experience in different industries, we can assist you in developing your project according to your needs with the best technology.

If you want to discuss solutions that fit your company needs, connect with me through mail or LinkedIn.

Robson Marzochi

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