15 parts per million quality defects and beyond: how ZF uses Simcenter Anovis for near perfection

By Elif Altuntop Kavas

ZF traces its roots back to 1915, when it was founded as “Zahnradfabrik GmbH” (gear factory) to manufacture high-quality precision gear systems for Count Zeppelin’s airships. These early transmissions were critical to the performance of the massive dirigibles, marking the beginning of ZF’s legacy in high-performance driveline technology. Over a century later, ZF has evolved into a global leader in mobility solutions. Today, as the automotive industry transitions to electric mobility, ZF continues to lead: this time in partnership with Siemens, redefining quality assurance for the electric age.

ZF: From airships to e-mobility solutions

From gearboxes to electric drives

ZF’s legacy includes milestones like the 4HP and 9HP transmissions and the first five-speed gearbox in Formula 1. Now, the company is applying its expertise to hybrid and electric powertrains, supplying components to major OEMs worldwide.

To maintain its high standards in this new era, ZF uses Simcenter Anovis, Siemens’ advanced end-of-line (EOL) testing solution. Already integrated into over 50 global test benches and expanding toward 100, Simcenter Anovis is central to ZF’s quality control strategy.

Simcenter Anovis system for end-of-line quality testing

Meeting the challenge of e-mobility

Producing over 10,000 transmissions and electric drive units (EDUs) daily, ZF faces the challenge of ensuring each unit meets strict OEM specifications especially in noise, vibration, and harshness (NVH). Unlike ICE vehicles, electric drivetrains don’t mask imperfections with engine noise, making NVH issues more noticeable and harder to resolve.

ZF’s solution is a comprehensive quality process powered by Simcenter Anovis. This system combines sensors, signal analysis, and flexible software to detect even the most subtle defects before products leave the line.

End-of-line quality testing of electric drive units via Simcenter Anovis

A longstanding partnership

ZF and Siemens have worked together for over two decades, evolving from early modular systems to today’s digital platforms. Weekly meetings and close collaboration ensure that new features and improvements are quickly implemented. One major improvement is the order-based cepstrum metric for end-of-the-line fault detection, co-developed by ZF and Siemens. Once a complex manual process, it’s now automated within Simcenter Anovis.

“It took all of us on the team, along with the Siemens experts, days of analysis work and troubleshooting in the past. Today, in Simcenter Anovis, a novice can do this special type of cepstrum analysis work. All they have to do is set the limits correctly and use the cepstrum curve and it works in ten minutes.”

Franz Knoppik, acoustical engineer at ZF

Simcenter Anovis integrated into ZF test bench software

Tangible results

The partnership has delivered impressive results:

15 parts per million (PPM) defect rate across global production
Reduced OEM penalties, which can range from $100 to $5,000 per rejected part
Faster fault detection through advanced signal processing
Streamlined testing using a master configuration adaptable to various products of OEMs

These outcomes not only protect ZF’s bottom line but also strengthen its reputation for quality in a competitive market

Scaling quality for the electric era

ZF is applying its proven ICE quality processes to electric drivetrains. With Simcenter Anovis, the company can quickly adapt to new product lines and customer requirements.

“You hear everything with an electric driveline,” says Knoppik. “There is no masking anymore. You need to find the root cause and a fast solution.” Simcenter Anovis enables ZF to analyze the full NVH spectrum, identify issues early, and ensure every EDU meets the highest standards.

Simcenter Anovis system integrated into the ZF test bench

People powering progress

ZF’s team blends deep NVH knowledge with fresh perspectives on electrification. This mix of experience and innovation is key to their success.

“As German engineers, we must be fast, faster than our competitors. That’s why our partnership with Siemens, weekly meetings, and fast alignments are so important.”
Andreas Steffensky, team leader at ZF

This agile approach allows ZF to stay ahead of the curve, continuously improving its processes and adapting to the rapid pace of change in the automotive industry.

A blueprint for the future

ZF’s story is more than a case study, it’s a model for how legacy manufacturers can thrive in the age of electrification. By combining deep expertise with advanced tools like Simcenter Anovis, and fostering a collaborative, forward-thinking culture, ZF is not only meeting today’s demands but also shaping the future of mobility.

Learn how ZF and Siemens have partnered for over 20 years to achieve 15 parts per million quality defects for global production:

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