A New Approach to Machine Commissioning

Machine development is usually sequential: Mechanical design, electrical design, and automation are performed one after the other. If a mistake is made anywhere in the development process and isn’t detected, the error costs grow by a factor of ten per phase of development.

 Virtual commissioning greatly reduces this risk.

During the development of a machine, there are many risks that can jeopardize the ability to introduce the machine into production on schedule. So why wait until the final assembly to begin interdisciplinary verification of the machine

Virtual commissioning from Siemens makes it possible to conduct machine commissioning tests early in the development phase.

What-if scenarios can be tested with no risks involved, the engineering error quota gets reduced, and the security validated – before the real machine even exists.

Problems or errors detected in a virtual environment do not cause expensive repairs, and during the real machine assembly, the virtual machine can be used for testing and debugging of the PLC code – enabling a more effective and flexible use of resources.

Faster Commissioning

The digital twin of the new machine permits the parallelization of mechanical design, electrical design, and automation engineering, so that there’s no more waiting for upstream phases to be completed. It also makes it possible to perform virtual commissioning in a digital development environment in the office instead of on site with the real machine at the plant operator’s location. Thanks to machine simulation, comprehensive tests can be run to detect and correct design and functional errors, enabling the real commissioning to be completed in a shorter timeframe.

Limits Error Costs

The Six Sigma management system states that the cost of errors grows by a factor of ten per development step. Because virtual commissioning can be performed parallel to engineering, knowledge from simulations and tests can help improve engineering quality early on. Testing the real PLC program using virtual controllers increases the certainty that the controller will function exactly as the customer expects during the real commissioning – and helps to avoid high error costs.

Reduces Risk of Real Commissioning

When problems occur during real commissioning, it wastes time, personnel, and materials. In the case of international projects, expenditures are even greater. During virtual commissioning, however, everything can be tested risk-free without the participation of personnel from the customer’s plant. Thanks to thorough troubleshooting, the risk of errors or defects in the real machine is significantly reduced.

Book your discovery call today

Experience the benefits that the virtual commissioning software from Siemens can bring to your business and learn how the software package can help you to streamline your machine development process.