Seamless Traceability in Brake Disc Manufacturing
How Breyden uses CAQ to link product, process, and quality data by serial number.
Breyden manufactures more than 13 million brake discs a year at its Breidenbach site.
For the iDisc® I, material, process, and inspection data are linked by serial number across the entire production process.
From Casting to Final Inspection: Fully Documented
At Breyden, traceability doesn’t start with final inspection. It accompanies every iDisc® I from casting through machining and coating to final inspection.
For coated brake discs in particular, material, process conditions, and inspection results must be clearly traceable to a single component. To achieve this, Breyden maps the entire production chain digitally. Every iDisc® I is assigned a digital twin in which the relevant data from all production steps come together.
iDisc® I: High Requirements for Process Control and Traceability
Breyden has been producing the iDisc® I in series since 2017. A tungsten-carbide-based hard-metal coating makes the brake disc especially resistant to wear and temperature and protects it against corrosion.
With the development of the iDisc® I for Porsche, requirements for traceability and documentation increased significantly. All product- and process-relevant characteristics had to be clearly assigned to the individual component.
Manufacturing requires precise coordination of material, coating, and machining. For this reason, end-to-end traceability across the entire production chain was implemented for the iDisc® I from the outset.
iDisc® I Benefits at a Glance
- High resistance to wear and temperature
- Protection against corrosion
- Stable coefficient of friction
- Longer service life
- Lower particulate emissions
Digital Process Control with CAQ
The CAQ system is at the core of traceability. Every iDisc® I receives its unique identity as soon as the DataMatrix code is applied. The serial number links material data, process parameters, and inspection results.
Measurement data from sensors and inspection technology feed directly into the CAQ system and are assigned to the respective brake disc. When defined deviations occur, the system immediately triggers the predefined response, such as removal from the line, rework, or blocking.
Machining centers and other production systems are also integrated, creating a continuous data flow between manufacturing and quality assurance.
The process in six steps:
- Identify
- Capture
- Link
- Evaluate
- React
- Document
The Serial Number Connects All Quality Data
The serial number is generated by the CAQ system and permanently applied to the brake disc during laser marking. It serves as the common reference point for all production- and quality-relevant information.
This allows every iDisc® I to be traced down to individual production and inspection steps. In the event of a complaint or recall, the relevant data is immediately available. At the same time, this creates complete quality documentation for audits, customer requirements, and internal analyses.
Continuously Developed Together Since 2005
Breyden has relied on the CAQ system from Quality Miners since 2005. The solution has since been expanded step by step and closely integrated with manufacturing and SAP.
In addition to classic CAQ processes, equipment, marking systems, and measuring stations have been integrated. As a result, master, transaction, process, and quality data are available for the relevant processes without media discontinuities.
The CAQ system is connected to SAP, machining equipment, marking systems, measuring stations, and further peripherals. This brings together master, transaction, process, and quality data across the entire production process.
Technical highlights:
- SAP integration
- OPC UA connectivity for relevant equipment
- Digital twin for every iDisc® I
- Real-time evaluation with qs-STAT
- Integration of external machining steps
iDisc® II: Traceability for Euro 7 Requirements
With the iDisc® II, requirements for documentation and process control increase once again. The new generation is designed to further reduce particulate emissions, extend service life, and improve corrosion protection.
Following the successful implementation for the iDisc® I, Quality Miners was awarded the contract in 2025 to equip iDisc® II production with end-to-end traceability as well. This includes an additional production line, SAP connectivity, equipment integration, and the expansion of the existing CAQ system.
The experience gained from ongoing series production of the iDisc® I feeds directly into the new production line.
“Our close collaboration with Quality Miners has accompanied us for many years.
Following the successful implementation of traceability for the iDisc® I, we are currently working together on implementing it for the iDisc® II.”
Jan-Claus Wagner Mechanical Machining / Planning, Breyden GmbH
About Breyden GmbH
Breyden manufactures high-quality brake discs and cast components at several sites in Hesse. More than 13 million brake discs are produced each year at the Breidenbach site. Lollar is home to additional production and machining facilities, while Ludwigshütte houses the brake disc innovation center.
What the Solution Enables Today
- Seamless traceability for every iDisc® I
- Clear assignment of material, process, and inspection data
- Immediate response to defined process deviations
- Continuous data flow between production, quality assurance, and SAP
- Complete quality documentation for audits and complaint cases
Quality That Runs Alongside Production – Not Checked Afterward
At Breyden, traceability is not a downstream documentation process. Material, process, and quality data accompany every iDisc® I through production and are available wherever they are needed.
This means quality is not only checked at the end but is assured throughout production. This is precisely what distinguishes pure documentation from integrated quality assurance.
Success Story for Download
You’ll find all the key information on digital traceability and production at BREYDEN summarized concisely in our success story.
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Michael Schäfer
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F +49 721 6652 – 346
m.schaefer@quality-miners.de
Alexander Klein
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F +49 721 6652 – 348
a.klein@quality-miners.de
