Virtual Commissioning
Test PLC logic, robot programs, and sequences before the physical machine line is ready
The Problem
Many companies face similar challenges when trying to create value from their technical data and processes.
When an entire machine line is first tested in reality, it's often too late to discover expensive errors. PLC logic, robot programs, safety, and mechanics only truly meet on the shop floor, and commissioning becomes a mix of waiting, hotfixes, and guesswork.
These challenges often result in concrete problems:
- Software cannot be tested realistically before hardware is ready
- Bottlenecks and sequence errors are discovered late when changes are expensive
- Commissioning depends on who is present and what can be tested
Why It Matters
Why does this matter? Look at the broader impact:
Late errors cost in stops, extra hours, rework, and delays. Virtual commissioning moves troubleshooting and verification earlier, so startup becomes predictable instead of improvised.
Key metrics we focus on:
Number of issues at FAT/SAT
Time in commissioning
Repeated stops after handover
Our Solution
Here's how we approach the solution:
Digital model of the machine line with simulation of flow, stations, and critical movements
PLC/robot logic tested against simulation, validating software without waiting for physical hardware
Sequence and bottleneck verification, where cycle times, interlocks, and deviations are tested systematically
Test cases and acceptance criteria so 'it works' becomes documentable and repeatable
Results
The comparison between the starting point and the result shows the concrete value the solution can create.
Line is first tested when everything is physical, and problems appear late
Critical flows and logic tested in virtual setup before physical startup
The concrete results include:
- Fewer surprises because sequences and interlocks are validated early
- Faster and more controlled startup because test cases already exist
- More stable operation after handover because errors aren't first discovered in production
Want to test the machine line before it's on the floor?
We can help analyze your situation and identify opportunities for similar solutions.