From dashboard fatigue to digital twin clarity: Opcenter X Intosite at Siemens Healthineers
Breaking through the complexity barrier
At Siemens Healthineers’ High Energy Photonics Center (HEP) in Forchheim, Germany—a facility spanning the size of eight European soccer fields—complexity is the name of the game. Manufacturing advanced medical imaging and X-ray tube technology demands precision, real-time visibility, and seamless collaboration across multiple teams. Yet despite having substantial digital infrastructure in place, the team faced a persistent challenge: how do you make complex operational data intuitive and accessible to everyone on the shop floor?
As Markus Kaupper, Head of Digitalization at Siemens Healthineers HEP Center, explains: “Even though we have made substantial advancements in the field of data availability, real-time digital twinning and KPI visualization, our processes remain complex. We needed a more intuitive, immersive way of interacting with status information and KPIs for our processes and equipment.”
The answer wasn’t more dashboards. It was a complete reimagining of how teams interact with their digital factory.
Moving beyond dashboards to immersive collaboration
Siemens Healthineers didn’t settle for incremental improvements. Working collaboratively with Siemens Digital Industries Software, the HEP team made a bold decision: transition from traditional dashboard-driven monitoring to a Digital Twin collaboration model powered by Opcenter X Intosite—a cloud-based solution that transforms how production teams visualize and interact with real-time data.
Think of it as upgrading from a static map to a live, interactive 3D map. With Opcenter X Intosite, operators and managers can navigate through a digital replica of their production environment, clicking on tagged objects to instantly access embedded product Digital Twins, status reports, production line information, documents, and even videos—all location-based and in real time.
As Hakan Senkaya, Project Manager for Metaverse initiatives at Siemens Healthineers, reflects on the partnership:
The partnership with Siemens was agile and dynamic, and we were able to share multiple ideas and deliver requests directly to the Opcenter X Intosite team.
Hakan Senkaya, Project Manager for Metaverse Initiatives, Siemens Healthineers HEP Center
Real results: speed, transparency, and proactive operations
The pilot rollout has already delivered measurable impact:
Faster Decision-Making With location-based information displayed exactly where it’s needed on the production floor, reaction times are projected to improve by 20 to 25 percent—a significant gain in an industry where every second counts.
Enhanced Quality Control The HEP team can now monitor critical environmental parameters—temperature, humidity, equipment condition—in real time directly onsite. As Sebastian Grimm, Head of Manufacturing X-ray Tube, notes: “We can check environmental parameters such as temperature and humidity at specific production locations. The location-based data are displayed at the right place, which gives us further advanced transparency.”
Proactive Maintenance By synchronizing live status and equipment performance rates in the digital shadow, teams can shift from reactive to proactive maintenance, simplifying processes and reducing unplanned downtime.
Democratized Data Access Currently supporting 30 to 40 active users across supply chain management, equipment lifecycle management, and R&D, Siemens Healthineers aims to scale to over 200 users plantwide. This democratization of data empowers front-line workers and supervisors to make informed decisions instantly.
The innovation that makes it work
What sets Opcenter X Intosite apart is its intuitive design combined with powerful functionality:
- Place markers and color coding highlight critical status areas, helping users quickly identify issues
- Built-in search functionality makes it easy to locate equipment across the massive facility
- Virtual tours onboard new users seamlessly
- Immersive visualization of the digital performance twin creates an entirely new way to understand operational data
As Markus Kaupper emphasizes:
The most innovative contribution Opcenter X Intosite has made is the immersive visualization of the digital performance twin, which provides a whole new way for everyone to interact with and understand operational data.
Markus Kaupper, Head of Digitalization, Siemens Healthineers HEP Center
Looking ahead: the metaverse-enabled factory
Siemens Healthineers isn’t stopping here. The team is working toward a fully digital and virtual master control room where all relevant KPIs will be centralized for efficient monitoring, while on-floor users access the same insights via tablet or touchscreen. Early exploration of AI and large language models shows promising potential for even deeper integration.
As Jens Fuerst, Principal Key Expert in Digitalization & Automation, states: “Unifying the Siemens Healthineers manufacturing ecosystem into one digital solution is our north star.”
Ready to Transform Your Production Environment?
Siemens Healthineers has proven that the future of manufacturing isn’t about collecting more data—it’s about making data accessible, intuitive, and actionable for everyone. Whether you’re managing complex medical device production or any sophisticated manufacturing operation, immersive Digital Twin collaboration can revolutionize how your teams work.
Explore the full Siemens Healthineers Opcenter X Intosite case study to discover the complete transformation story and implementation insights.
Learn more about Opcenter X Intosite and how immersive visualization can drive operational excellence in your facility.
