Key Takeaways

• Operational Optimisation: 21% increase in AGV fleet utilisation with significantly reduced idle times.
• Efficiency Uplift: 38% reduction potential in operational carbon emissions through fleet and charging optimisation.
• AI Recommendation Engine: Actionable insights for fleet scheduling, charging windows, and capacity planning.
• Real-Time Monitoring: Edge devices provided live visibility into AGV energy consumption and operational cycles.
• No Rip and Replace: Mavarick's platform integrated seamlessly with existing VWG systems and infrastructure.
• Standardised Data Layer: Asset Administration Shell structured emissions data aligned to global standards.

Executive Summary

Volkswagen Group’s (VWG) Dresden facility the "Transparent Factory", partnered with Mavarick to optimise AGV fleet operations, maximise fleet availability, and reduce the operational carbon footprint of the plant.

By deploying Mavarick's Fleet Intelligence platform above existing systems, the project delivered a 21% increase in AGV fleet utilisation, a 38% efficiency uplift, and significant reductions in operational carbon emissions, without replacing any existing infrastructure.

Mavarick connected live production data, AGV telemetry, and charging infrastructure to make real-time decisions on fleet scheduling, charging windows, and capacity planning. The result: reduced idle times, optimised energy use, and a measurable step toward VWG's "goTOzero" 2030 targets.

This project demonstrates that production-aware fleet intelligence, layered above existing systems, can deliver meaningful operational and sustainability improvements at scale. VWG Dresden is already extending these methods across additional sites.

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Client Testimonial  

We looked for an innovative solution provider to address the carbon footprint of the product so we decided upon Mavarick and are convinced of their advanced analytics technology”
–Dirk Theime, Head of New Mobility and Innovations  

“Mavarick’s speed of implementing changes and their ability to find other ways for a solution is really impressive. We’re very, very impressed with their approach and with the way they work”
–Johannes Rönsberg, Innovation Management  

About the Client

Volkswagen Group (VWG) has long been a pioneer in redefining the automotive landscape. Renowned globally for its blend of tradition and innovation, VWG consistently adapts to the evolving demands of a sustainable future.  

A testament to this commitment is the Dresden facility, often referred to as the “Transparent Factory.” This state-of-the-art facility is dedicated to assembling electric vehicles and piloting green technologies, serving as a testbed for innovative solutions to reduce emissions and enhance operational excellence.

In 2017, VWG further cemented its leadership in sustainable mobility with the construction of the E-Mobility Station at the Dresden facility. This innovative hub provides an extensive network of charging points for electric vehicles and showcases Volkswagen’s vision of a sustainable and connected transportation ecosystem.  

Designed as a public-facing initiative, the E-Mobility Station enables visitors, customers, and employees to experience firsthand the convenience and efficiency of electric mobility. The station not only supports the adoption of e-vehicles but also aligns seamlessly with VWG’s ambitious “goTOzero” sustainability strategy, which aims to achieve net-zero emissions across its operations.

By partnering with Mavarick, VWG Dresden underscored its commitment to leveraging advanced technology to meet its sustainability goals. Together, the two organisations are redefining what’s possible in automotive manufacturing and mobility innovation.

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Challenges

The growing complexity of AGV fleet operations at VWG Dresden created two interconnected challenges, operational inefficiency and carbon exposure, both invisible without real-time intelligence across the plant.

Fleet and Charging Decisions Made Without Production Intelligence

AGV charging and task scheduling decisions were made without visibility of live production demand, leading to suboptimal fleet utilisation, unnecessary idle time, and avoidable energy and carbon costs. Addressing these inefficiencies was essential to maximise fleet availability and maintain production continuity while reducing the plant's operational carbon footprint.

No Visibility Across Fleet Operations and Energy Use

Data collection across operational assets was fragmented and inconsistent,  making it impossible to identify inefficiencies, measure energy consumption accurately, or take targeted action. Without a unified view of fleet operations and energy use, VWG could not build the operational intelligence foundation needed to optimise performance or report on emissions with confidence.

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Mavarick’s Approach

The Fleet Intelligence Solution

 Mavarick deployed its Fleet Intelligence platform above VWG's existing systems, connecting live production data, AGV telemetry, and charging infrastructure to optimise fleet operations in real time.

• Operational Visibility: Mavarick’s Fleet Intelligence platform provided continuous visibility into the carbon emissions generated by operational assets such as the factory AGVs. This enabled the VWG team to identify carbon emissions inefficiencies and take actions to mitigate emissions.
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• Production-Aware Optimisation: Machine learning algorithms processed the collected data to uncover patterns and provide actionable insights. These included recommendations for optimising fleet utilisation and charging schedules to reduce carbon emissions.
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• Asset Administration Shell:  By leveraging the Asset Administration Shell, Mavarick ensured emissions data was structured in a standardised data layer, making it easier to comply with global standards.
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• Real Time Monitoring: Mavarick’s edge devicesprovided real-time data on operational assets such as AGV energy consumption,carbon emissions, and operational cycles. This provided a robust foundation forcarbon footprint calculations.

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Implementation

1. Data Collection and Integration: Mavarick’s edge devices were installed on operational assets including the AGVs and charging points. These devices seamlessly connected to VWG’s existing systems, integrating carbon emissions data into the AAS framework for real-time visibility and reporting.
2. Deployment of Data Management Platform: A custom platform was developed to monitor carbon emissions and energy use, enabling VWG to pinpoint high-emission activities and evaluate the impact of changes in real-time.
3. Validation and Testing: Over a 5-month period, data was rigorously tested to ensure accuracy. The implementation and testing period validated that the proposed solutions could achieve meaningful emissions reductions and comply with reporting standards.

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Key Outcomes

• Operational Optimisation: 21% increase in AGV fleet utilisation, significantly reduced idle times.
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• Efficiency Uplift: 38% reduction potential in operational carbon emissions.
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• No Rip and Replace: Seamlessly integrated with VWG's existing systems and infrastructure.
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• Improved Reporting: Enhanced Scope 2 emissions reporting aligned to international standards.
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• Fleet Intelligence Platform: Centralised real-time visibility across AGV operations, energy, and carbon.

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Volkswagen Group’s partnership with Mavarick enabled them to harness advanced data management technologies, driving smarter carbon management and setting a benchmark for sustainability excellence in the automotive industry.

See what Fleet Intelligence can deliver in your plant.

Book a live demo with Mavarick.

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