DPI Suite

DPI (Digital Production Intelligence)

A true digital twin for production machines, based on bi-directional data communication for digitisation and efficiency gains in manufacturing.

Why is it different from the usual "Digital Twin"?

While most industrial digital twins are really just simulations or visualisations, the DPI Suite creates a true two-way data link between physical production and its digital counterpart. This means that the digital model is in live contact with reality: any changes are immediately reflected, and the results of simulations can feed back into actual production.

This difference enables companies to test developments, production design modifications or even new product launch scenarios using a "Test before Invest" approach based on rapid prototyping. Decisions are thus not only faster and cheaper, but also significantly safer.

Developer

IDM-Systems Zrt. (Hungary) - developer of advanced digital twin technology and DPI Suite software framework, developer of T800 testbed environment.

Motivation

In a fast-changing industrial environment, production planning, product development support and short cycle time introductions are key to staying competitive. Firms must respond to new customer needs with increasing frequency, while ensuring a quality-cost-time optimum.

Digital twin technology allows production processes to be monitored, predicted and optimised in real time. The "Test before Invest" - also known as rapid prototyping - approach offers a particular advantage: companies can test ideas in a virtual environment, validate solutions at PoC (Proof of Concept) or Pilot level before actually investing, and thus get to a working concept quickly, at lower cost and with lower risk.

The aim of the development

The project aims to create a DPI Suite that synchronises real and digital manufacturing environments, providing an integrated platform for simulation, validation, experimental prototyping and rapid testing of manufacturing processes.

The main modules of the system:

  • DPI-SP (Systems Platform) - a framework that integrates the two twins.
  • DPI-ED (Edge) - physical machine data collection on Edge computer.
  • DPI-VE (Virtual Edge) - Virtual Edge module linked to the digital twin.
  • DPI-VM (Validation Module) - validation module for synchronisation of real and digital twins.
  • DPI-CA (Cycletime Analyser) - cycle time analysis module for optimising production processes.

The DPI Suite supports iterative development based on design thinking: users can quickly test their ideas in a virtual environment (e.g. T800 testbed), then validate and transfer the tested solutions to real production. This integrated approach accelerates the introduction of new products and supports the manufacturing and validation process.

Expected technological impact

  • Full digital twinning with real-time two-way data connection.
  • Modular and extensible software architecture that can be extended with energy efficiency and quality control modules.
  • The possibility of simulation and validation without interrupting production.
  • Pilot prototype design and rapid testing (Pilot, PoC) to accelerate product development.
  • Predictive maintenance using artificial intelligence.
  • Root-cause analysis and cycle-time optimisation.
  • Providing a "Test before Invest" approach that provides reliable decision support with low risk.

Expected economic impact

  • Significant reduction in production costs and downtime.
  • Faster production planning and product development support, shorter conversion times.
  • Lower investment risk through PoC and Pilot level validation.
  • Cost savings by detecting errors in advance ("fail fast, fail cheap" principle).
  • Increased productivity through continuous simulation and optimisation.
  • Environmental benefits: lower energy consumption and waste.
  • Thanks to the "Test before Invest" approach, companies can get to validated solutions faster and at lower cost.