SPOT AT ZF FRANCE
Idefix: The New Reliable Solution for Safety and Maintenance
How ZF Active Safety France is redefining industrial excellence through 24/7 autonomous robotics
From Tradition to Digital Transformation: An inside look at how the ZF Bouzonville plant is transforming industrial inspection and safety through autonomous robotics with Spot.
ZF Active Safety France, a key subsidiary of the German group ZF Friedrichshafen specializing in automotive braking systems is undergoing a major technological mutation.
As part of its global digitalization strategy, the site has transitioned from a traditional industrial setup to a modern and connected factory model. In this context, the Spot robot (nicknamed “Idéfix“) has been integrated as a cornerstone of this digital transition, serving as a high-tech tool to execute the plant’s automation and data-driven strategy.
Spot: One Robot, Two Critical Roles
By integrating Boston Dynamics Spot robot, the objective is clear: to automate low value-added tasks so the workforce could focus on operational excellence.
To achieve this goal, ZF identified two critical missions: increasing the frequency of maintenance inspections and raising safety standards to the highest level. Traditional inspections were constrained by human availability (one per shift) and high reliance on costly external services.
After a rigorous site assessment, the Boston Dynamics Spot robot was selected for its unique ability to navigate stairs, tight spaces, and hazardous areas where traditional AMRs fall short, while also capturing critical operational data to support and continuously feed ZF’s preventive maintenance strategy.
Industrial Inspection: The Eye of Precision
In its first month alone, Spot detected 39 air leaks, allowing for immediate repairs and energy savings.
Lionel Champlon, Plant Manager
Idefix doesn’t just walk; it analyzes. Equipped with advanced cameras and sensors, it performs:
- Visual Monitoring: Automatic reading of gauges and filter status
- Thermal Inspection: Real-time monitoring of motors and pumps to prevent overheating
- Acoustic Imaging: Spotting and locating invisible compressed air leaks in assets
Safety & HSE: Spot ensures 100% reliability in security rounds (24/7):
- Constant Vigilance: Verifying extinguisher presence and ensuring safety exits are clear
- Autonomous Escalation: If an anomaly is detected, an automatic alert is sent to maintenance for immediate action
Proven Efficiency, Tangible Growth
The implementation of Idéfix is not just a technological feat; it’s also a financial success:
RAPID PAYBACK
The project achieved a payback period of just 0.96 years. The automation of inspections has generated significant savings through the rapid detection of anomalies, allowing for immediate and optimized maintenance interventions.
NON-STOP RELIABILITY
Transitioning from one manual inspection per shift to 24/7 automated continuity, ensuring zero gaps in surveillance.
TRACEABILITY
Every mission generates digital reports with pictures and precise data, creating a transparent and unalterable history of plant health.
ATTRACTIVENESS
This project has boosted customer interest and positioned the Bouzonville plant as a benchmark for innovation within the ZF Group. The French facility was honored with the 2025 Excellence Award for Innovation in recognition.
The Role of Intuitive Robots
Technical Expertise Behind the Scenes
The successful rollout of this project was made possible through the strategic support of Intuitive Robots. As ZF’s technological partner for this initiative, Intuitive Robots managed the end-to-end implementation:
- Operational Readiness: Comprehensive training for site teams to ensure total autonomy and optimal robot acceptance by staff.
- Custom Integration: Development and adaptation of specific AI algorithms to meet ZF’s industrial requirements, including automated gauge reading and leak reporting.
- Strategic Support: From the initial site assessment to the deployment of 100% autonomous missions, Intuitive Robots acted as the architect of this robotic transformation.
Intuitive Robots is proud to collaborate with ZF Active Safety France to make the Spot robot project a lasting success.