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Shopfloor Visualization-Oriented Digitalization of Heterogeneous Equipment for Sustainable Industrial Performance

Author

Listed:
  • Alexandru-Nicolae Rusu

    (Department of Manufacturing Engineering, Transilvania University of Brasov, 5 Mihai Viteazul, 500036 Brasov, Romania)

  • Dorin-Ion Dumitrascu

    (Department of Automotive and Transport Engineering, Transilvania University of Brasov, 1 Politehnicii, 500036 Brasov, Romania)

  • Adela-Eliza Dumitrascu

    (Department of Manufacturing Engineering, Transilvania University of Brasov, 5 Mihai Viteazul, 500036 Brasov, Romania)

Abstract

This paper presents the development and implementation of a shopfloor visualization-oriented digitalization framework for heterogeneous industrial equipment, aimed to enhance sustainable performance in manufacturing environments. The proposed solution addresses a critical challenge in modern industry: the integration of legacy and modern equipment into a unified, real-time monitoring and control system. In this paper, a modular and scalable architecture that enables data acquisition from equipment with varying communication protocols and technological maturity was designed and implemented, utilizing Industrial Internet of Things (IIoT) gateways, protocol converters, and Open Platform Communications Unified Architecture (OPC UA). A key contribution of this work is the integration of various data sources into a centralized visualization platform that supports real-time monitoring, anomaly detection, and performance analytics. By visualizing operational parameters—including energy consumption, machine efficiency, and environmental indicators—the system facilitates data-driven decision-making and supports predictive maintenance strategies. The implementation was validated in a real industrial setting, where the solution significantly improved transparency, reduced downtime, and contributed to measurable energy efficiency gains. This research demonstrates that visualization-oriented digitalization not only enables interoperability among heterogeneous assets, but also acts as a catalyst for achieving sustainability goals. The developed methodology and tools provide a replicable model for manufacturing organizations seeking to transition toward Industry 4.0 in a resource-efficient and future-proof manner.

Suggested Citation

  • Alexandru-Nicolae Rusu & Dorin-Ion Dumitrascu & Adela-Eliza Dumitrascu, 2025. "Shopfloor Visualization-Oriented Digitalization of Heterogeneous Equipment for Sustainable Industrial Performance," Sustainability, MDPI, vol. 17(17), pages 1-17, September.
    • Handle: RePEc:gam:jsusta:v:17:y:2025:i:17:p:8030-:d:1743563
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    References listed on IDEAS

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    1. Angelo Corallo & Vito Del Vecchio & Marianna Lezzi & Paola Morciano, 2021. "Shop Floor Digital Twin in Smart Manufacturing: A Systematic Literature Review," Sustainability, MDPI, vol. 13(23), pages 1-24, November.
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