From Complexity to Clarity: Boosting Axle Production Efficiency with a Modular Digital Ecosystem at Škoda Auto
Business Impact
- Dramatically reduced assembly inconsistencies thanks to real-time validation at every step
- Fully paperless process across warehouse and production floor, increasing speed and traceability
- Faster onboarding with intuitive visual guidance and built-in worker verification
- Instant access to live production data, improving shift planning and response times
- Scalable digital foundation ready for AI, digital twin applications, and data-driven decision-making
About Škoda Auto
- In 2024, delivered more than 926,000 vehicles to customers worldwide
- Operates three production plants in the Czech Republic; has production capacities in China, Slovakia and India, mostly through group partnerships, as well as in Vietnam and Ukraine in cooperation with a local partner.
- Has been part of the Volkswagen Group, one of the world’s most successful car manufacturers, for more than 30 years.
- Employs around 40,000 people worldwide and is active in almost 100 markets.
The Challenge: When Speed Meets Fragmentation
Axle production at Škoda Auto operates under high time pressure—each task must be completed in under a minute, leaving no room for delays or inaccuracies. The process relied on printed labels with general codes and physical bulletin boards for verification, which added manual steps and potential for miscommunication.
At the same time, the underlying setup reflected the typical complexity of large-scale manufacturing: teams worked with different systems and documentation standards, data consistency was a challenge, and the need for uninterrupted production made system changes harder to implement. A lack of a dedicated test environment and natural caution toward change further shaped the project landscape.
To maintain precision and efficiency at scale, Škoda Auto set out to introduce a solution that would simplify complexity—ensuring that every part reached the right place at the right moment with confidence.
Get Inspired: 5 Steps to Digitally Transform Complex Production
- Start with mindset, not machines
Real transformation begins when users believe in it. Engage operators early and show them the value of change. - Bridge the gap between business and IT
Cross-functional collaboration ensures that technical solutions meet real operational needs. - Define roles and responsibilities early
Clear ownership and documented processes lay the foundation for scaling and support. - Roll out without shutting down
Parallel implementation allows new systems to go live while production keeps moving. - Treat go-live as the beginning, not the end
Continuous feedback, real-time data, and daily optimization are key to long-term impact.
[.infobox][.infobox-heading]The Solution: Digitizing the Axle Line from End to End[.infobox-heading]With support from Trask, Škoda Auto replaced fragmented, paper-based processes with a connected digital ecosystem that brings real-time guidance to operators, instant insights to supervisors, and full traceability to production. The result is a faster, more reliable axle assembly line—ready for scaling, automation, and future innovation.[.infobox]
Before
- Part selection
Manual picking based on printed codes; required bulletin board lookups - Process visibility
Limited oversight, delayed reaction to issues - Inconsistency handling
No immediate alerts; inconsistencies discovered late in the process - Training & onboarding
Time-consuming, inconsistency-prone; reliance on peer support - System integration
Fragmented systems, inconsistent data - Documentation & traceability
Paper-based tracking, low transparency
After
- Part selection
Guided digital selection with real-time validation - Process visibility
Live dashboards and instant feedback at every workstation - Inconsistency handling
Immediate warnings with visual and audio signals - Training & onboarding
Visual instructions, login-based task validation, faster onboarding - System integration
Unified, modular ecosystem with seamless data flow - Documentation & traceability
Digital records and full process traceability
Despite the complexity of the task and the need for several iterations, Trask successfully delivered a solution tailored to our needs. The project required flexibility and ongoing adjustments, but thanks to a responsive and collaborative approach, we reached a functional outcome. After final refinements, the system performs as expected and provides a solid foundation for future development.
Jana Vydrová – Manager of Digitalization in Production of Components, Škoda Auto
Ready to simplify complexity in your production? Let’s explore how a modular digital ecosystem can work for you.
