Digital Virtualization Experience (DiVE) Suite

Industry Challenges

In the era of Industry 4.0, true competitive advantage will be achieved by organizations that know how to invest in the one resource with the greatest potential: data. Unlike many valuable resources, data is not limited, and it is already out there waiting to be analyzed and harnessed for the greater manufacturing good. But the increasing volume and variety of available data does not automatically translate into value. Companies that have invested in digitalization but have not implemented solutions to extract valuable insights from their digital ecosystems are losing a huge opportunity for operational optimization and business growth.

With this in mind, the Engineering Group presents its Digital Virtualization Experience (or DiVE) Suite, a holistic Industrial Internet of Things (IIoT) technology platform composed of application-focused solutions for industrial asset integration, industrial process connection and performance intelligence. Part of the Engineering Group's Digital Enabler Internet of Things (IoT) ecosystem, the DiVE Suite was designed to meet the unique needs and challenges of the industrial market.

Based on technologies capable of collecting and analyzing asset performance data and leveraging the Engineering Industries eXcellence division's unique experience delivering and implementing the Digital Thread for Industry 4.0, the DiVE Suite enables organizations to monitor industrial asset performance, integrate different manufacturing operations, detect and identify anomalies ahead of issues, and anticipate and avoid quality losses.

The main components of the DiVE Suite are:

DiVE Foundation: delivers administration services and user interfaces for all DiVE modules.
DiVE Virtual Plant: enables the connection of industrial assets, implementing the most common communication protocols and easily integrating new ones.
DiVE MAPs: enables real-time performance monitoring and analysis of line/unit behavior.
DiVE Early Warning: performs anomaly detection and identifies trend deviation via machine learning analysis.
DiVE HMI: enables smarter and easier use of manufacturing applications all throughout the plant.
DiVE Labeling: enables management of all labeling phases, from ERP order to final pallet balance.

The main technological features of the DiVE Suite are:

Modular, scalable (horizontal/vertical) and distributed architecture
Central portal for all user and role configuration across hosted applications
No-code configuration of synoptics and dashboards
Centralized monitoring and control of configured assets
Easy integration with third-party systems
Built-in sets of supported communication protocols for data collection
(Optional) deployment leveraging major Cloud platforms (Microsoft Azure, Google Cloud, Siemens MindSphere)
Integration with leading Manufacturing Execution Systems (MES) (Siemens Opcenter, AVEVA System Platform, DGS MES)

The main advantages of the DiVE Suite platform are:

Non-intrusive, easy-to-implement offering
Technology-agnostic platform
Fully configurable modules
Legacy-system compliant
Easy integration and device abstraction
Accurate and comprehensive analysis of data
Innovative work experience for end users

Main DiVE Suite Components

1. DiVE Foundation

DiVE Foundation is a single digital portal from which all administration services and user interfaces are managed and delivered for all the DiVE Suite modules.

Multi-layer asset visualization
User registration and access control
Application aggregation hub
Configuration and editing of dashboards and synoptics
Site mapping configuration

2. DiVE Virtual Plant

DiVE Virtual Plant is a digital interface that provides a standard layer of communication for all applications and equipment that are integrated in the manufacturing context.

Data abstraction from source and protocol
Quick and easy access to data
Data persistence
Data filtering through configurable expressions
Collection and standardization of heterogeneous shop floor data
Event notification
Edge device virtualization

3. DiVE MAPs

DiVE MAPs is a monitoring application that provides production performance data and enables the detection of current or failure conditions.

Real-time line/station/asset monitoring
Plant visibility and control
Plant condition analysis
Bottleneck detection
Key Performance Indicators (KPI) configuration
KPI trend analysis and reporting

Source: Engineering Group's Digital Virtualization Experience (DiVE) Suite

4. DiVE Early Warning

DiVE Early Warning is a digital application that uses Artificial Intelligence algorithms to train a model that learns the correct behavior of the asset being monitored.

Current and historical data analysis
Asset condition monitoring
Anomaly and trend detection
Potential malfunction identification
Early warning alerts
Signal classification

5. DiVE HMI

DiVE HMI is a smart devices manager that enables users to utilize different applications in an easier way all over the plant.

DiVE HMI enables the operator to use a wearable device, e.g. a smart watch, as a mobile machine/process/system interface in the production environment
DiVE HMI Viewer is an interactive terminal that acts as a data display and allows notification of a production operation or event
DiVE HMI Andon is a multi-media panel used to present quality or process data to personnel on the production floor

6. DiVE Labeling

DiVE Labeling is a digital application that enables management of all product labeling phases, from ERP order integration to final pallet and balance labeling.

Automatic and manual pallet labeling
Printer configuration and integration
Material traceability data management
Quality and regulatory standard compliance
Specific label management (barcode or QR code)
Integration with ERP, MES and/or Warehouse Management Systems (WMS)

Target Industry Sectors

Automotive and heavy equipment
Textile manufacturing
Metals and mining
Food and beverage manufacturing
Packaging and consumer goods
Water distribution services

Main Features of the DiVE Suite

Connect different assets and equipment via the most common communication protocols
Collect and standardize heterogeneous data sources
Virtualize the production floor by enabling read and write operations
Integrate different manufacturing systems and operations into a centralized hub
Leverage the smart devices manager for quick and easy access to any business application
Use single portal for authentication/authorization functions, application aggregation and configuration of synoptics and dashboards
Calculate Overall Equipment Effectiveness (OEE) and other KPIs
Visualize relevant performance data on configurable dashboards
Monitor real-time and historic asset data to support predictive maintenance
Automate the detection of current or imminent asset failure conditions
Automate alerts and event notifications when acquired signals deviate from the norm
Enable intelligent data analysis via integration of Machine Learning applications

Main Benefits of the DiVE Suite

Maximize Return on Assets (ROA)
Minimize bottlenecks
Reduce unplanned asset downtime
Optimize operational processes
Minimize maintenance costs
Reduce energy costs
Maximize throughput
Improve asset performance
Increase visibility across operations
Increase system interoperability

Engineering's Expertise

The DiVE Suite is the result of a project aimed at designing and delivering a smart, modular, flexible and Industry 4.0-compliant suite of technology products to the industrial market. With an application framework based on best-in-class technology platforms, the DiVE Suite enables companies to digitally collect and analyze field data, predict and prevent potential malfunctioning of machines and tools, and anticipate and prevent negative trends in the quality of their manufacturing processes. Engineering Industries eXcellence is proud to leverage and deliver this dedicated IIoT platform to help organizations across all manufacturing sectors worldwide connect critical assets, collect and analyze asset data within a secure environment, and use that data to improve their business processes and results in a tangible way.