MAN Truck & Bus SE

The MAN Trucks Plant Cracow demonstrates with its Digital Use Case “AI BOOST for new parts parametrization” how artificial intelligence can be applied in a targeted way to solve a specific operational problem. The starting point was a highly manual and time-consuming parametrization process for new and updated part numbers. As a result, the process was not only resource-intensive but also prone to human error.

The root causes primarily lay in technical interface limitations, a lack of process automation, and high parameter complexity. Interdependent parameters had to be entered repeatedly. In addition, the process frequently required switching between different systems. This led to media disruptions, recurring manual activities, and avoidable process losses.

With the objective of reducing parametrization time by at least 30 percent, automating repetitive tasks, and developing an AI-based tool for the control-data environment, the plant initiated a collaboration with counterpart in Munich plant, MAN headquarter, and the MAN Digital Hub. Together, they developed an AI model tailored to the plant’s requirements, built a web application for model further training, and introduced a new parametrization process based on a dedicated AI tool.

The technical solution combines machine learning with domain-specific rule-based knowledge. It includes, among other elements, a multi-model ensemble with dynamic confidence assessment, chained multi-target prediction, an automated retraining process with model versioning and evaluation criteria, as well as a feedback loop based on validated prediction data. The web application makes input data, predicted parameter values, confidence levels, and feedback transparent, thereby supporting traceable human-AI collaboration.

What is particularly convincing is that the solution was not implemented as an isolated digitalization project but directly addresses a bottleneck in the value stream. New part numbers can now be parametrized more regularly and simultaneously. The process is accelerated, errors are reduced, and employees are relieved of recurring manual tasks.

The results achieved exceed the defined target: through the introduction of the AI tool, parametrization time has already been reduced by 40 percent. In addition, the accuracy of the model’s predictions continues to improve. At the same time, future-oriented competencies in working with AI models have been built up, and a robust standard for the parametrization of new part numbers has been established.

The plant thereby demonstrates how lean and digitalization can work together: stable processes, clear standards, and an adaptive digital solution improve speed, quality, and repeatability at the same time. The project demonstrates the strong impact of the MAN Production System (MNPS) on this Digital Use Case, contributing to all five MNPS principles.

The use case is also convincing in terms of sustainability and scalability. The AI tool improves its quality over time by analyzing new data and automatically refining itself. There is potential for use in other areas where parameters need to be set. The insights gained are shared through the exchange of experience, making it possible to identify further potential fields of application.

The Digital Use Case from MAN Trucks Plant Cracow combines a clear operational need with a technically sophisticated and practical AI solution. The solution reduces manual effort, improves process quality, creates transparency regarding the quality of AI predictions, and enables a continuous learning process. For this outstanding combination of lean, artificial intelligence, and sustainable process improvement, MAN Trucks Sp. z o.o., Plant Cracow, receives the Automotive Lean Production Award 2026 in the “Digital Use Case” category.

MAN Truck & Bus SE is one of Europe's leading commercial vehicle manufacturers and a provider of transport solutions. As part of the TRATON GROUP, the company develops and manufactures trucks, buses, vans, engines, and digital mobility services. In 2025, MAN continued to focus on the transformation of the transport industry through investments in electrification, automation, digitalization, and zero-emission technologies. The company generated €13.7 billion in revenue and employs approximately 33,000 people worldwide, serving customers across Europe and international markets.

The MAN Trucks Kraków plant in Niepołomice near Kraków is the largest truck production facility within the MAN manufacturing network in Europe and one of the most modern truck assembly plants worldwide. Since its opening in 2007, the site has played a key role in supplying MAN vehicles to customers across Europe and other international markets. In 2025, the plant employs approximately 3,850 people and produces all MAN truck series, from light distribution vehicles to heavy-duty long-haul trucks. Following increased demand, the plant introduced a three-shift operation and raised output to around 225 trucks per day, with a technical capacity of up to 300 vehicles daily. In 2025, the site surpassed the milestone of 350,000 trucks produced, underlining its strategic importance for MAN's European production network.

Address
ul. dr Rudolfa Diesla 1 32-005 Niepołomice Poland

Products
MAN TGX, TGS, TGM, TGL trucks and eTGL; customized vehicles via Truck Modification Center (TMC)

Employees
Approx. 3,850 (including temporary workers)