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Liebherr enhances operational efficiencies with next-generation I/O module

Zühlke helped the construction machine manufacturer to realise a future-proof I/O module, ensuring Liebherr´s market leading position.

The project at a glance

With a critical input/output (I/O) module facing end of life, Liebherr needed a modern solution to ensure operational continuity and enhanced efficiencies.

Zühlke combined deep domain expertise, structured consulting and planning, and comprehensive testing to develop the next-generation I/O module.

A seamless transition to the new I/O module ensured long-term reliability and operational efficiency, reducing maintenance costs and increasing productivity for Liebherr and its customers.

Liebherr seeks technology partner to ensuring long-term operational viability and meet evolving demands.

Liebherr is a global leader in construction machinery, facing the challenge of replacing one of their outdated input/output (I/O) modules with a next-generation solution. Zühlke provided the necessary expertise and resources to ensure a smooth transition, enhancing the operational efficiency and reliability of Liebherr’s machinery for decades to come.

Liebherr's I/O modules are essential to operations since they connect key components – like hydraulic valves, sensors, and revolution counters – to its central control unit. Many of these modules had been in production and use for more than 20 years, with key electronic components set to be discontinued.

Replacing them with a modern solution was therefore a business imperative – key to ensuring long-term operational viability, improving functionality, and meeting the evolving demands of the construction machinery market.

But to do so, Liebherr needed to navigate some core constraints:

The team had limited time, resources, and in-house expertise.
Ensuring downward compatibility with existing machinery would be key to minimising disruption to production and operations.
The replacement module needed to bring enhanced flexibility and functionality to the machinery, supporting the firm’s commitment to innovation and reliability.

Comprehensive approach overcomes resource constraints and improves project planning

Reinforcing Liebherr’s team with experienced software engineers and a project manager, we were primed to navigate the resource constraints and deliver the project effectively in line with the manufacturer’s goals. Our solution included several key elements:

Structured planning

Zühlke structured the project backlog, improving planning and resource allocation, ensuring that all tasks were prioritised and managed efficiently.

Enhanced communication

By prioritising team and stakeholder communication, Zühlke ensured that all parties were aligned, facilitating smoother project execution and increasing collaboration efficiency.

Rigorous testing and support

Zühlke's engineers provided architecture consulting, development, and automated testing. They implemented system testing to ensure downward compatibility and early bug detection, ensuring the new module met all technical requirements and integrated seamlessly with existing systems.

Our team’s strategic approach and technological expertise were pivotal in developing a next-generation I/O module that met Liebherr’s stringent requirements.

Ensuring the long-term viability and reliability of Liebherr’s construction machinery

The partnership between Liebherr and Zühlke was key to the successful delivery of this project. The transition from legacy to next-generation I/O module was executed flawlessly, allowing production to commence as planned and maintaining operational continuity.

Zühlke helped to upskill Liebherr’s engineers in relevant technologies, ensuring the team could manage and maintain the new system effectively. New functionality – made possible by the new module – enhanced the I/O capabilities, while code refactoring and improved documentation has given the team more effective ways to maintain the new software.

“The discontinuation of various components was putting our operations at risk. Zühlke helped us develop the new module rapidly, with a qualified and motivated team spanning project management, architecture, and engineering, helping us meet the tight schedule for modernizing.”
Heiko Krautter
Head of Industrial Controls, Liebherr

The successful implementation of the next-generation I/O module has had a profound impact on Liebherr and its customers. For Liebherr, the new modules ensure the long-term viability and reliability of construction machinery, aligning with the firm’s vision of providing innovative and high-quality solutions. The enhanced functionality and maintainability of the new modules translates into lower maintenance costs and increased efficiency, providing significant operational benefits.

For Liebherr’s customers, the improved I/O modules means the enhanced performance and reliability of their construction machinery, leading to reduced downtime and higher productivity. The flexibility of the new modules also enables easier integration with various software, offering customers a more versatile and adaptable solution.

Helping Liebherr ensure long-term operational efficiency and reliability

The collaboration with Zühlke enabled Liebherr to continue delivering on its promise of excellence and innovation, ensuring its machinery remains at the forefront of the industry.

By reinforcing Liebherr’s team and providing comprehensive support, Zühlke helped the company transition to a next-generation I/O module seamlessly, ensuring operational efficiency and reliability for years to come.