Case Study - Industry

300+ APIs centralized.
14 plants connected.

How a DAX-40 industrial group with 45,000 employees transformed its fragmented API landscape in 6 months — from OT/IT silos to a unified platform.

Company Profile

Industry Mechanical Engineering / Automotive
Employees 45,000
Locations 14 plants worldwide
Revenue EUR 8.2B
APIs before 300+ (undocumented)
Project duration 6 months
Compliance IEC 62443, TISAX, NIS2
75%
Faster system integration
12 weeks -> 3 weeks
92%
Fewer OT/IT tickets
340/month -> 27/month
100%
API documentation up to date
Before: 37% covered
EUR 2.4M
Saved per year
Licensing and personnel costs

Starting Point

14 plants, 300+ APIs, zero visibility

An OT/IT landscape grown over decades with isolated interfaces, high support costs, and compliance risks.

When the new CTO took over in 2024, he found an API landscape that had grown organically over 20 years. Each plant operated its own MES, SCADA, and ERP interfaces.

The result: over 300 APIs existed, but only 37% were documented. New integration projects routinely started from scratch.

We had 14 plants, each with its own APIs, its own docs, its own access processes. When an OT engineer left, we didn't just lose a person — we lost the knowledge behind dozens of interfaces. - CTO / Head of Industrial IoT

// The Challenge

Three core blockers in the API transformation

Knowledge silos, ticket floods, and missing auditability had stalled any scaling effort.

Knowledge silos and attrition

Interface knowledge lived with individuals. When experienced OT engineers left, critical integration details were lost.

Avg. 12 APIs undocumented per departure

340+ support tickets per month

The IT service desk was overwhelmed with API access and documentation requests. A large share was Self-Service-eligible.

60% Self-Service-eligible

Compliance risk

Without a central audit trail, IEC and TISAX audits required lengthy manual preparation.

6 weeks audit preparation

Implementation

6 months from kickoff to rollout

Structured rollout in four phases — from pilot plant to scale.

Phase 1 - Month 1-2
Discovery and pilot plant
API inventory at the pilot plant, first CI/CD synchronization, security zones documented.
47 APIs captured Pilot Plant South GitLab CI/CD
Phase 2 - Month 2-3
Standardization and compliance
Governance policies, templates, and role-based access for OT, IT, and partners established.
Governance Framework RBAC IEC 62443
Phase 3 - Month 3-5
Rollout to 14 plants
Phased rollout in sprints, supplier Self-Service activated, 300+ APIs centrally documented.
300+ APIs Supplier Portal Edge Sync
Phase 4 - Month 5-6
Optimization and scaling
Lifecycle automation, analytics live, audit passed, supplier onboarding significantly reduced.
TISAX passed 3-day onboarding Analytics live

Solution Approach

Three pillars of the transformation

The API Portal was introduced as a strategic OT/IT platform — not an isolated documentation tool.

Central API Catalog

Unified documentation, Try-it-Out, and fast discoverability for all API stakeholders.

Security by Design

Security levels, RBAC, and audit trail for regulatory traceability.

Automated Lifecycle

CI/CD synchronization, versioning, and breaking-change checks reduce operational risk.

Results

Measurable results after 6 months

Verified by internal controlling and confirmed in audit.

Integration Vorher: 12 weeks
3 weeks
Average integration time
Self-Service documentation and sandbox significantly reduce coordination overhead.
Support Vorher: 340 / month
27 / month
OT/IT support tickets
Access, documentation, and example requests are absorbed by the portal.
Onboarding Vorher: 6 weeks
3 days
Supplier onboarding
Partners get productive faster through Self-Service and clear approval processes.
ROI Vorher: distributed
EUR 2.4M
Annual savings
Less friction, lower operating costs, and faster integration cycles.

Voices from the Project

What stakeholders say

Perspectives from strategy, operations, and partner integration.

"

The portal has significantly accelerated our OT/IT convergence. The team now works on innovation instead of searching for documentation.

Dr. Martin W.
CTO / Head of Industrial IoT
"

New OT engineers find relevant APIs in minutes today. Security levels and versions are transparently traceable.

Sandra K.
Head of OT Engineering
"

As a supplier, we completed our first test integration in just a few days — that used to take weeks.

Thomas R.
Integration Lead, Tier-1 Supplier

Technology Stack

Technologies and standards used

OpenAPI 3.1 AsyncAPI 3.0 OPC UA gRPC / Protobuf MQTT 5.0 IEC 62443 TISAX NIS2 SAP S/4HANA Azure IoT Hub GitLab CI/CD OAuth 2.1 / OIDC

Key Learnings

Takeaways from the project

The most important lessons for organizations with complex API landscapes.

01

Start small, scale fast

A pilot plant generated measurable value early and eased the company-wide rollout.

02

Involve OT early

Domain teams were not just informed but actively integrated into structure and processes.

03

Compliance as a product feature

Auditability was baked directly into governance and lifecycle instead of being bolted on later.

04

Prioritize Self-Service

The biggest ROI came from fewer follow-up questions and faster integration paths.

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