Industrial machines produce operational data every second, yet much of it is never evaluated. The fault log lists every follow‑up error and has to be read by hand, and how well a machine really runs at the customer site often remains a matter of opinion.
The DDAS Machine Insight Suite records equipment performance directly on the CODESYS‑based controller: OEE with availability, performance and quality, machine states and runtimes, and the top ten stops by duration and by frequency. The data is recorded automatically, not estimated; the KPIs are built on the established OEE formulas.
The software runs on the machine, but the main beneficiaries are the OEMs and system integrators who build, commission and support it. They decide which insights reach the machine owner, and in what form.
OEMs and system integrators: the main beneficiaries
The suite gives machine builders a consistent way to see how their machines perform in real operation.
- Figures instead of anecdotes. Efficiency, losses and stops become measurable, shift by shift and run by run.
- Better engineering decisions. Data from real operation replaces assumptions about the design and the control logic.
- Ramp‑up with figures. During commissioning, the KPIs show where the machine loses time and when it reaches stable operation.
- Service based on facts. Service teams look at recorded states and stops instead of reconstructing them from the fault log.
- A foundation for a service business. Performance summaries and efficiency evaluations for your customers, while you keep the implementation.
You decide the level: you connect the signals, such as the piece counter, stops and states, for a machine, a module, a unit or a whole line, and the KPIs apply to that level.
OEMs do not resell the suite. They use what it records to offer value‑added services to their customers.
Sharing insights without handing over your tools
OEMs often do not give machine owners direct access to their internal performance tracking. The reason is practical: it protects the customer relationship.
Raw performance data is easy to misread. Every machine runs below its optimum during warm‑up, changeovers, unstable production, operator errors or material issues. Seen without context, such data can lead to:
- unnecessary complaints
- wrong conclusions about the quality of the machine
- pressure on the OEM for issues that have nothing to do with the machine
- misunderstandings about normal production fluctuations
The suite delivers the data on the controller. You decide what your HMI, your displays and your service team show, and which selected insights you share with the machine owner. That way you can:
- provide useful information with context
- strengthen the customer relationship
- offer performance summaries and efficiency evaluations
- build a service business around machine transparency
- keep control of the software and the logic behind it
What machine owners gain from shared insights
When OEMs share selected information, machine owners gain practical advantages:
- Where the time goes. Availability, performance and quality per shift show where the machine loses output.
- What to tackle first. The top ten stops by duration and by frequency point to the stop types worth a closer look, a starting point for maintenance and process improvements.
- Batch planning with shifts and breaks. The expected batch end time is calculated from the remaining parts and the OEE, with your shift and break calendar, up to one week ahead.
- Comparable figures. The last 21 runs stay available on the controller for comparison.
A licensing model built for OEMs
Licensed once for your whole company: unlimited machines of your own build and unlimited projects, no runtime fees and no per‑machine fees. At a fraction of what it costs to build, test and maintain it yourself. For lines with machines from other manufacturers, the DDAS Machine Insight Suite SL in the CODESYS® Store licenses a single controller.
Once integrated, the recording runs on every machine you build with it, for the machine’s whole life. The suite keeps the last 21 runs on the controller; long‑term storage is up to you, in your own systems.
Professional and Enterprise include twelve months of maintenance: new feature levels, bug fixes and compatibility updates. Renewing it each year is optional. DDAS provides free security updates for five years from the release of your feature level, with or without maintenance.
Conclusion
On the controller. In your tools. Under your control. The Machine Insight Suite gives OEMs and system integrators recorded performance data from real operation, and a foundation for better machines, better support and new services, while the implementation stays with them.
Test the application template in demo mode, on your own controller: request the demo.