Solution 5 - WeldWise

Within the Danube DNA project, the ICT Cluster, together with COMICON, developed WeldWise — a modular digital solution designed for monitoring production processes and energy consumption in industrial environments.

WeldWise was created to provide SMEs with a practical and lightweight system for collecting, visualizing, and analyzing operational data directly from production equipment. The solution connects machine activity, production events, and energy usage into a unified monitoring platform that supports better operational transparency and data-driven decision-making.

The system enables:

• Automated monitoring of electricity consumption,

• Production counting by machine and shift,

• Calculation of specific energy consumption per produced unit (Wh/unit),

• Real-time operator dashboards,

• KPI visualization and historical analytics for management,

• Alerts, reporting, and export of operational data.

WeldWise is based on a modular architecture that combines compact hardware components with open-source software technologies. The solution uses local edge infrastructure, MQTT communication, Node-RED processing logic, and Domoticz-based visualization tools, allowing flexible adaptation to different industrial processes and machine types.

A key advantage of the system is its ability to improve visibility of production and energy-related processes without requiring complex or expensive factory-wide upgrades. By providing real-time insight into machine operation, energy efficiency, and production performance, WeldWise supports SMEs in reducing manual reporting, identifying inefficiencies, and improving operational control.

The solution also creates a strong foundation for future integration with ERP, MES, and AI-based analytics systems, contributing to the broader goals of digital transformation and smart manufacturing within the Danube region.