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    fischer Hydroforming

    fischer Hydroforming is a subsidiary of the globally active fischer group that specializes in metal forming and is one of the leading suppliers of hydroformed components. Using this forming technology, the company manufactures complex, high-precision metal components— particularly for the automotive, commercial vehicle, and motorcycle industries, as well as the aerospace and equipment manufacturing sectors. The focus is on lightweight construction, high strength, and maximum design freedom.

    fischer-group-400x200
    Industry

    Industries

    Metalworking, Stainless Steel Processing, Automotive Supplier Industry
    Objective

    Target Industries

    Manufacturing and Mechanical Engineering, Automotive Industry
    Employees

    Employees

    Approximately 2,700 worldwide
    PG-Proalpha-400x200

    Proalpha GmbH

    www.proalpha.com

    Factory

    Industries

    Industry 1, Industry 2, Industry 3

    Objective

    Target Industries

    Industry 1, Industry 2, Industry 3

    Team

    Employees

    Number

    en_stefan-geissler-fischer-hydroforming_80xx800

    “We didn’t want a one-size-fits-all template for the PCF—we wanted a system that allows for a parallel assessment of costs and CO2 emissions. Our goal is a transparent Product Carbon Footprint that enables both our customers and us to drive change. To that end, we plan to integrate even more suppliers and measurement data in the future and also explore alternatives such as more sustainable raw materials.”

    Dr. Ing. Stefan Geißler
    CEO, fischer Hydroforming

    Highlights

    PCF at the Push of a Button

    To reliably and accurately calculate the carbon footprint of each individual product while making the best possible and most efficient use of and integrating existing systems, fischer Hydroforming, in collaboration with Enit ,hasdeveloped its own precise PCF methodology.

    AI for Better Energy KPIs

    Best Practice: fischer Hydroforming, in collaboration with Enit and our sister company Nemo, has launched an innovative project that demonstrates how artificial intelligence (AI) and automated data analysis help reduce energy consumption, optimize processes, and cut costs.

    A Pioneer in Energy and CO2 Management

    fischer Hydroforming demonstrates how AI and data mining can transform energy and production data into valuable insights. We are proud to have a client like fischer Hydroforming as a reference customer, as they exemplify true innovation at every level.

    What was the
    initial situation?

    As an energy-intensive company, fischer Hydroforming operates in a dynamic market environment—one characterized by highly volatile energy prices, growing pressure to reduce emissions, and high demands for transparency throughout the supply chain. With processes such as hydroforming, heat treatment, and cleaning, primary energy consumption stands at around 10–11 GWh. Previous analyses—often Excel-based—reached their limits: manual analyses, delayed responses to deviations, and heavy reliance on personnel. The need for better data utilization became apparent—both for efficiency and for the carbon footprint.

    Why the decision
    Enit?

    Enit stood out thanks to its seamless integration into the existing IT landscape and an intuitive system that employees quickly became familiar with. Starting with energy monitoring enabled high-resolution data analysis, which served as a solid foundation for further steps such as PCF calculation. Using Nemo’s AI software, production data, ERP data, and energy data could be linked, allowing processes to be evaluated holistically for the first time. The PCF is now calculated in real time, automatically, and in an audit-proof manner—right down to the CO2 rate per machine hour.

    How can success
    be measured?

    • More measures, implemented faster —thanks to rapid effectiveness monitoring and early alerts in the event of deviations.
    • Verified emissions data —the PCF was validated by GUTcert with no discrepancies.
    • Less effort, more insights – manual analyses have been replaced; the PCF “just runs on its own.”
    • Sales with genuine consulting value —scenarios such as changes in wall thickness can be calculated directly.

    Enit Benefits

    Fully Integrated Instead of Extra Work

    Enit’s energy monitoring system integrates seamlessly into the existing infrastructure—no additional measurement technology (unless required for submetering), no duplicate data collection. The data is collected automatically in the background, enabling analyses, cost savings, and providing the basis for CO2 assessments.

    From Energy Consumption to Concrete Leverage Points

    A precise breakdown of energy and emissions data (e.g., IHU: 41% share of total consumption) yields optimization strategies that can be implemented immediately—ranging from the operating modes of individual machines to the composition of emulsions.

    Reliable Data for Credible Statements

    All results of the carbon footprint assessment are documented in an audit-proof manner, are verifiable, and provide the basis for well-founded sustainability communication—both internally and with customers.