Bosch Rexroth: Reducing Energy Costs by 20-30% to Drive Sustainable Manufacturing with Splunk

In today’s manufacturing landscape, sustainability and operational efficiency are no longer optional—they're essential to innovation and competitive advantage. Bosch Rexroth, a global leader in industrial automation from Germany, has set a new benchmark by pivoting to unified, data-driven insights, transforming its energy management strategies.

Watch how together with Splunk, Bosch Rexroth is now driving measurable business results and environmental impact:

The Challenge: Visibility in a Fragmented Landscape

Operating across diverse IT and OT (Operational Technology) environments, Bosch Rexroth faced a common hurdle: siloed data. Without unified, real-time visibility into energy consumption, costs, and carbon emissions, the team struggled to identify inefficiencies or meet ambitious sustainability targets.

Thomas Fechner, Member of the Executive Board and Factory Automation Lead at Bosch Rexroth, framed the challenge clearly: “We reached a point where siloed and fragmented data was no longer sufficient. We needed a unified and real-time data access to energy consumption for all our factories to improve.”

The Solution: A Unified Data Strategy

By integrating Splunk Enterprise with the help of implementation partner Consist Software Solutions, Bosch Rexroth was able to leverage the Splunk Sustainability Toolkit and real-time data from Electricity Maps, to create a centralized energy management solution. This architecture bridges the gap between IT and OT, providing a holistic view of the factory floor.

Driving Efficiency: The Three Levers of Optimization

Bosch Rexroth utilised three key levers to transform their operations:

• Energy Optimization: Shifting idle machinery into standby mode to eliminate waste.
• Cost Avoidance: Leveraging AI/ML-driven alerts to prevent peak energy surcharges.
• Smart Scheduling: Aligning energy-intensive tasks with periods of lowest prices and carbon intensity.

Tangible Business Outcomes

The results speak for themselves:

• 20–30% reduction in energy costs (EUR)
• 10–15% reduction in energy use (kWh)
• 25–30% reduction in greenhouse gas emissions (CO2e kg)

Driving the Future of Manufacturing with IT-OT Convergence

Looking ahead, Bosch Rexroth’s journey with Splunk underscores the exciting potential of IT-OT convergence. Combining Splunk’s best-in-class analytics with Bosch Rexroth’s expertise in industrial connectivity unlocks unparalleled opportunities for efficiency, transparency, and sustainability.

As Thomas Fechner aptly put it, “By introducing the Splunk Platform, we get a high leap in observability. Without the implementation, it would still look fragmented and isolated, and we could not gain the holistic improvements. Now we are rolling it out into our plants to have more automation of all these processes, gaining the benefits of transparency, observability, and of course, putting AI on top.”

What’s Next?

The partnership doesn’t stop with energy use cases. According to Harald Lukosz Referent Product Area Stage at Bosch Rexroth, “We did this in particular for energy use case here, but you can do it also for quality inspection, anomaly detection, and all the other things where you can gain massive benefit in manufacturing.”

As Bosch Rexroth continues to roll out the Splunk Platform across its factories, their vision for sustainable and efficient manufacturing becomes increasingly tangible. With energy optimization as the first step, they’re poised to unlock even greater value through AI and automation.

Learn More

Bosch Rexroth’s success story demonstrates the transformative power of Splunk in manufacturing operations. By providing real-time observability into energy use, costs, and emissions, Splunk empowers organizations to align sustainability goals with tangible business outcomes.

Ready to see how Splunk can elevate your operations and learn how we’re helping global leaders like Bosch Rexroth reimagine what’s possible with data?

• Read the full story and watch the success video here
• See more amazing customer stories
• Download Splunk’s latest State of Observability Report