Convergix standardizes machine data with on-machine performance monitoring platform

Convergix Automation Solutions identified a recurring issue among its OEM and system integrator (SI) customers: while machine data was widely available, it was often inconsistent, poorly structured and difficult to use for decision-making.

Many customers attempted to build dashboards and monetise data early, but without a reliable data foundation, these efforts delivered limited value. In addition, traditional predictive maintenance approaches focused on detecting faults close to failure, leaving insufficient time for corrective action.

To support more effective digitalisation, Convergix set out to create a solution that prioritised clean, contextualised machine data as the basis for performance analysis and future AI applications.

Developing an on-machine performance monitoring platform
To address these challenges, Convergix developed “Intuition,” an on-machine performance monitoring platform deployed as a standard feature across its machines. The system is designed to collect, structure and contextualise machine data at the source before applying advanced analytics.

The platform is built on FactoryTalk Optix from Rockwell Automation, selected for its flexibility, OPC UA connectivity and ability to operate fully on-premises. Data is stored in time-series and relational databases and visualised through dashboards, with tagging structures defined in collaboration with process experts.

This architecture creates a consistent and standardised data layer across machines, independent of controller type or customer environment.

Moving from fault detection to performance insight
Rather than focusing on predicting imminent failures, the solution targets early indicators of performance degradation. By monitoring trends and deviations in machine behaviour, operators can identify issues earlier in the fault cycle and take corrective action before failures occur.

The platform also supports remote support capabilities, machine-to-machine comparisons and plant-level visibility. Because it operates fully on-premises, it addresses customer requirements for data ownership, security and independence from subscription-based cloud services.

Enabling consistent data across OEM and SI environments
A key objective of the project was to standardise data collection practices across diverse customer environments. By establishing a single, consistent data layer, Convergix enables OEMs and system integrators to deliver more reliable insights and services to end users.

This approach also reduces barriers to adoption, as customers receive immediate operational value without the need for complex data integration or external analytics platforms.

Measurable impact and scalability
The implementation of Intuition has delivered several operational benefits:

Foundation for AI-ready time-series analysis
The solution has also been extended beyond new machines to retrofit projects across existing facilities, demonstrating its scalability.

Building a foundation for AI-driven manufacturing
By focusing on clean, contextualised data at the machine level, Convergix has created a platform that supports future digital transformation initiatives. The system provides a structured basis for advanced analytics, machine learning and autonomous decision-making.

The case illustrates how standardising data collection and shifting focus from fault prediction to performance monitoring can unlock meaningful value from industrial data, enabling more proactive and efficient manufacturing operations.

Edited by Industrial Journalist, Romila DSilva, with AI assistance.