Digital Services Are Becoming a Core Element of Machine Building
Digital services are no longer a future trend—they are rapidly becoming an essential part of the value proposition offered by machine builders and system integrators. Today’s manufacturers are under constant pressure to improve machine efficiency, reduce downtime, and optimize operational costs. To achieve these goals, access to reliable machine and component data is critical.
Machine information enables OEMs to identify performance improvements, monitor machine health, and reduce unplanned downtime. This is particularly valuable during the warranty period, where service incidents can significantly increase support costs. However, the value of machine data extends far beyond commissioning and warranty support. When leveraged effectively, it provides benefits throughout the entire machine lifecycle.
More Than Maintenance: A New Opportunity for Customer Retention
The advantages of machine data are not limited to improving machine quality. OEMs can also use digital services as a strategic tool to strengthen customer relationships.
By offering ongoing visibility into machine performance, health, and operational data, machine builders can create additional service offerings that continue long after the warranty period has ended. These value-added digital services help customers maximize productivity while increasing the likelihood of long-term customer loyalty and repeat business.
As industrial customers continue their digital transformation journeys, expectations are changing. Many manufacturers now expect digital capabilities not only on new machines but also on equipment that has already been delivered and is currently in operation.
The Challenge of Retrofitting Existing Machines
Implementing digital services on new machines is often straightforward because connectivity and software functionality can be planned from the start. Retrofitting existing machines, however, can be significantly more challenging.
Complex software modifications within machine control systems can be costly, time-consuming, and potentially risky. In some cases, modifications may not even be feasible due to hardware limitations, legacy control systems, or operational constraints.
Another challenge is technology adoption. Many available solutions require tools, platforms, or programming environments that fall outside the expertise and comfort zone of machine programmers and service technicians. This can increase implementation complexity, training requirements, and project risk.
A Flexible Solution for Both New and Existing Machines
To address these challenges, DDAS offers a flexible digitalization solution that can be deployed on both new and existing machines.
The software components can be integrated directly into the machine control system, allowing machine programmers to work within their familiar development environment. Alternatively, the solution can be installed on an external PLC controller or edge device that utilizes the same or a very similar engineering environment as the machine control system itself.
This approach enables companies to adopt digital services without requiring teams to learn entirely new technologies or development workflows. The result is a practical and scalable solution that aligns with the existing skills and experience of machine programmers and service personnel.
Minimal Impact on Existing Machine Controls
When deployed on an external device, the requirements for the machine control system remain minimal. Typically, only a communication interface and a small set of machine data points need to be provided—capabilities that are already available in most modern machines.
Even in cases where these prerequisites are not readily available, DDAS's support specialists can work with customers to develop an individual implementation concept tailored to the specific machine architecture.
Why External Edge-Based Deployment Can Be a Smart Choice
Installing the solution on an external PLC controller or edge device offers several advantages:
- Long-term storage of historical machine data
- Simplified and low-risk software updates
- Modern deployment and rollout capabilities
- Standardized dashboards across multiple machines
- Connectivity for multiple machines through a single device
- A common solution for both new and installed machines
- Independence from the machine control system manufacturer
- Compatibility with virtually any existing machine control platform
This flexibility allows OEMs to standardize their digital service strategy across different machine generations and controller vendors while maintaining a consistent user experience.
Understanding the Cost Perspective
An external deployment architecture may introduce additional implementation costs. These can include:
- External hardware or edge device costs
- PLC runtime software licenses
- Communication licenses, such as OPC UA connectivity
However, these costs can often be offset by connecting multiple machines to a single device, reducing the overall cost per machine.
An important advantage of the DDAS approach is its licensing model: once implemented and licensed, customers benefit from long-term usage without recurring annual software fees for the installed device.
Conclusion
Digital services are rapidly becoming an essential part of the machine builder's portfolio, enabling OEMs to improve machine performance, reduce unplanned downtime, and create new value-added services throughout the entire machine lifecycle. At the same time, customers increasingly expect these capabilities not only on new equipment but also on machines already in operation.
DDAS addresses this challenge with a flexible solution that can be deployed either directly within a CODESYS-based machine controller or on an external PLC or edge device.
By leveraging familiar PLC technologies and engineering environments, machine programmers and service teams can implement digital services without the need to learn new platforms, significantly reducing implementation effort, risk, and training requirements. At the same time, all solution concepts are designed with cybersecurity in mind and consider the requirements of the Cyber Resilience Act (CRA), helping OEMs build secure and compliant digital service architectures for the future.
This practical approach allows OEMs to digitalize both new and existing machines, regardless of the underlying control system manufacturer. The result is a scalable foundation for machine data collection, performance optimization, and lifecycle services that strengthen customer relationships, reduce service costs, and support long-term business growth.