Technology & Production

From chaos to clarity: How ABB Busch-Jaeger turns months of process work into minutes

A process manager, 250+ processes and the transformation through AI-supported intelligence

The company

ABB Busch-Jaeger Elektro GmbH is Europe's leading manufacturer of electrical installation technology and smart home solutions. With over 1,200 employees and a turnover of more than 530 million euros, the company develops and produces innovative solutions for modern building technology.

"I felt like a piece of butter on 10 slices of bread"

Lisa Brückner, Head of Process Management at Busch-Jaeger, was faced with a seemingly impossible task: managing 250+ processes with minimal resources. Her biggest pain? The uncertainty as to whether her documented processes corresponded to reality.

The challenge in detail

Documentation = reality?

Comparison of the target processes in the company's own Quam system "SmarterPro" with the mined processes from Celonis.

Lost knowledge

Experienced employees retired - and took critical process knowledge with them.

Process variant chaos

Different departments had their own versions of the same processes.

Overload

A small team to check hundreds of processes - "like mowing the field with a scythe".

The transformation: from weeks to minutes

With aiio, Busch-Jaeger launched two groundbreaking proof of concepts that revolutionized process management.

PoC # 1: Process reality check with AI power

The task: To compare the order-to-cash documentation with real Celonis process data

‍Theproblem: No one knew whether the documented processes matched the actual reality.

The solution: aiio's AI agents analyzed both data sources and uncovered hidden truths:

Immediate error detection

The AI detected logical inconsistencies (packing before picking)

Gap analysis

Automatic identification of missing process steps in both systems

Harmonized flowchart

Combination of all information into a complete process picture

PoC #2: Process variant harmonization

The task: Combining two different manufacturing processes into a harmonized workflow

The result:‍

Automatic similarities/differences analysis
AI-generated role assignment (RACI matrix)
Suggestions for work instructions
Simulation-based optimization

The breakthrough thanks to Agentic AI:
The results speak for themselves

Dramatic time savings

"If I'd had to do it all in person, it would have taken a few weeks. Now we're down to minutes." - says Lisa Brückner herself about the results of the AI

Hidden errors uncovered

The AI found critical sequence errors in millions of Celonis implementations that were manually overlooked.

Regaining lost knowledge

Intelligent process comparisons have made buried company knowledge accessible again.

Neutral basis for discussion

"The AI is not on anyone's side. It makes a neutral suggestion based on the available knowledge."

Consistency and quality

Automatic check for BPMN conformity and best practices.

"I'm basically a process manager who tries to mow the field with a scythe. And the AI is actually the combine harvester that I was missing to mow the whole field in a fraction of the time."

Lisa Brückner
Head of Process Management
ABB Busch-Jaeger Elektro GmbH

The future: from fire extinguisher to strategic designer

Lisa's vision shows where the journey is heading:

AI assistants for process users

Intelligent search and contextual help

Co-pilots for process owners

Automatic opportunity/risk analysis and key figure proposals

Meta-analysis of the process landscape

Detection of missing interfaces and optimization potentials

Your path to process revolution

Imagine if your process management worked like this:

✅ Weeks become minutes
‍✅ Hidden problems become immediately visible
‍✅ Lost knowledge is regained
‍✅ Chaos becomes clarity

Ready for your own transformation?

Talk to us about your individual use case.
Let's work together to turn your process chaos into crystal-clear efficiency.

Find out more in the conversation!