Automation and Monitoring: OPC-UA Integration for Industrial Performance Visualization in AppVision

UltraVision Consult recently completed an advanced OPC-UA integration project for a food manufacturing facility, enabling seamless machine-level automation monitoring directly within the AppVision PSIM platform. The solution consolidates operational data from packaging machines into a single, centralized dashboard and delivers real-time visualizations, performance graphs, interactive timelines, and state-based diagnostics. By combining automation data with security oversight, this project demonstrates how PSIM platforms can bridge industrial and security systems to drive smarter, faster, and safer decision-making in demanding operational environments.

UltraVision Consult successfully implemented a smart automation monitoring solution for a packaging facility by leveraging OPC-UA protocol integration within the AppVision PSIM platform. The project aimed to centralize machine performance data in real time, creating a clear and actionable operational overview that supports both technical response and strategic decision-making.

Through this integration, the live status of every packaging machine is now pulled directly into AppVision. Each machine’s operating state, connection health, and number of processed units in the last three minutes are displayed and continuously updated every 30 seconds. This eliminates the need for scattered PLC interfaces and provides a unified view of the packaging floor, accessible to both facility managers and control room operators.

A custom dashboard was built to present:

• The current status of each machine
• A live graph showing production volume over the last three minutes
• A timeline bar marking operational states (run/stop/error)
• A pie chart of time spent in each state
• A live data table with machine-specific metrics

In addition to visualization, the system also includes automated email alerts in case of faults, historical error logging and analysis, and data export tools for traceability and reporting.

The added value of this solution lies in its cross-functional synergy. AppVision is traditionally used for managing alarms, video surveillance, and access control. By integrating with industrial automation systems via OPC-UA, it now empowers decision-makers with real-time operational intelligence within the same security interface.

This level of integration is especially critical in environments where downtime directly impacts output, and where collaboration between IT, OT, and security teams is essential. For the client, the solution not only improves responsiveness during incidents but also provides historical insights that support performance reviews, audits, and preventive maintenance.

UltraVision Consult continues to push the boundaries of what PSIM platforms can achieve by transforming them into central hubs for both physical security and operational excellence.