What does the Virtual Commissioning ROI calculator estimate?

It estimates net savings across engineering, FAT, and service phases based on project-specific assumptions such as hourly rates, rework risk, and commissioning time.

Who is the calculator for?

Machine builders, automation teams, and project leaders who need a customer-specific business case before investing in virtual commissioning or digital twin work.

Can I share or export my scenario?

Yes. You can save scenarios to file, share a link, or export a PDF report directly from the calculator toolbar.

Phase	Hours without VC	Reduction with VC	Hours saved	Extra savings	Gross savings	of total
Development	300 h	20%	60 h	DKK 0	DKK 0	0%
Test & FAT	250 h	30%	75 h	DKK 45,000	DKK 45,000	35%
SAT onsite	120 h	20%	24 h	DKK 82,500	DKK 82,500	65%

Phase

Hours without VC

Reduction with VC

Hours saved

Extra savings

Gross savings

of total

Development

300 h

20%

60 h

DKK 0

Test & FAT

250 h

30%

75 h

DKK 45,000

35%

SAT onsite

120 h

20%

24 h

DKK 82,500

65%

Optional Value Layer, Overview

Beyond the core Virtual Commissioning savings, the following optional value streams have been assessed. Included streams contribute to the combined potential.

Value stream	Status	Contribution
Sales & customer alignment	Not included	-
Marketing & interactive product demo	Not included	-
Training & onboarding	Not included	-
Documentation & knowledge reuse	Not included	-
Service & remote support	Not included	-
Future project reuse	Not included	-
Quality & rework risk	Not included	-
Operations & maintenance optimization	Not included	-

Value stream

Status

Contribution

Sales & customer alignment

Not included

Marketing & interactive product demo

Not included

Training & onboarding

Not included

Documentation & knowledge reuse

Not included

Service & remote support

Not included

Future project reuse

Not included

Quality & rework risk

Not included

Operations & maintenance optimization

Not included

Build a customer-specific Virtual Commissioning business case

Adjust a few project assumptions, review the net effect and open the evidence layer only when the conversation needs it.

Project setup

You only change assumptions. Calculations run automatically.

0 of 4 filled

Customer / project

Machine / system

Currency

Average hourly rate

VC project cost

Development

60 h

DKK 0

Hours without VC

Reduction with VC: 20%

Test & FAT

75 h

DKK 45K

Hours without VC

Reduction with VC: 30%

Extra calendar weeks saved

Weekly cost (excl. hours)

Extra weekly saving = extra calendar weeks saved × weekly cost

Saved hours capture person-hours. Extra calendar weeks capture additional calendar impact. Do not include the same saving in both places.

SAT onsite

24 h

DKK 83K

Hours without VC

Reduction with VC: 20%

Extra calendar weeks saved

Weekly cost (excl. hours)

Extra weekly saving = extra calendar weeks saved × weekly cost

Saved hours capture person-hours. Extra calendar weeks capture additional calendar impact. Do not include the same saving in both places.

Hours saved

159 h

Gross savings

DKK 128K

VC cost

DKK 0

Net effect

DKK 128K

VC cost share

Net return

N/A

Biggest value driver: SAT onsite with 65% of savings

How this is calculated

Transparent formulas behind the result

Hours savedHours without VC × Reduction with VC

Value of saved hoursHours saved × Average hourly rate

Extra weekly savingExtra calendar weeks saved × Weekly cost

Phase savingValue of saved hours + Extra weekly saving

Gross savingSum of all phase savings

Net effectGross saving - VC project cost

Net return on VC costNet effect / VC project cost × 100

VC cost share of gross savingVC project cost / Gross saving × 100

Saved hours capture person-hours. Extra calendar weeks capture additional calendar impact. Do not include the same saving in both places.

Business impact

Process flow

Visualisation of savings distribution across phases

Development

Hours saved60 h

Gross savingsDKK 0

0% of total

Test & FAT

Hours saved75 h

Gross savingsDKK 45K

Extra savingsDKK 45K

35% of total

SAT onsite

Hours saved24 h

Gross savingsDKK 83K

Extra savingsDKK 83K

65% of total

Net effect

DKK 128K

Evidence for the core VC impact

Sources that support the mechanisms behind the main calculator's Development, Test & FAT and SAT onsite impact. No fixed savings or endorsement implied.

McKinsey

IDTA

Logos and trademarks belong to their respective owners. References are for informational purposes only and do not imply partnership, sponsorship, endorsement, customer relationship, or guaranteed results.All logos and trademarks belong to their respective owners. References do not imply partnership, endorsement, customer relationship, or guaranteed results.

Evidence for the core calculation

Use this panel when the customer wants to understand assumption ranges, industrial examples and references behind the direct VC calculation.

Assumption guidance

Defaults are in the upper expected range based on published industry data. The table shows the span from conservative to ambitious assumptions.

Input	Conservative	Expected	Ambitious	Note
Development reduction	10%	20%	30-35%	Use higher values only when early simulation meaningfully reduces engineering rework.
Test & FAT reduction	20%	30%	40-50%	Use higher values only when PLC, robot logic, sequences, interlocks and machine behavior are tested virtually before physical FAT.
SAT onsite reduction	10%	20%	30%	Use higher values only when major logic, sequence, robot, operator-flow or integration risks are validated before onsite work.
Extra FAT weeks saved	0-0.5	1	1-2	Only include calendar/test-floor savings not already counted as person-hours.
Extra SAT weeks saved	0-0.5	1-2	2-3	Only include onsite, travel, accommodation, delay or opportunity cost not already counted as person-hours.

If you have historical project data, use it as a starting point. For new project types, the 'Expected' column is a good default. Adjust toward conservative for lower complexity.

Sources behind the Virtual Commissioning impact

These sources support mechanisms such as earlier validation, realistic simulation, reduced FAT/SAT debugging and lower risk of late changes in the core project.

Virtual commissioning cases

Tecnomatix robotics programming and simulation

Siemens describes virtual commissioning and robotics simulation for validating manufacturing cells with automation and robot logic before physical commissioning.

Use as mechanism evidence, not as a fixed savings promise.

Virtual commissioning cases

Estun Automation virtual commissioning case

Siemens reports 30% reduced onsite commissioning time and 20% lower overall costs in a digital manufacturing and virtual commissioning case.

Use as a relevant industry case, not as a universal default.

Industrial simulation tools

RobotStudio Suite

ABB positions robot simulation and offline programming as a way to build, test and refine robot cells before physical commissioning.

Robot-specific evidence; do not use as a generic VC default.

Industrial simulation tools

Manufacturing and real-time 3D

Unity supports manufacturing use cases for virtual design review, robotics simulation, training and interactive digital twin experiences.

Use as mechanism evidence, not as a fixed savings promise.

Industrial simulation tools

Asset Transformer

Unity Asset Transformer helps convert and optimize CAD, BIM, mesh and point-cloud data for real-time 3D visualization.

Use as mechanism evidence, not as a fixed savings promise.

Industrial simulation tools

Industrial digital twins and simulation

NVIDIA frames digital twins as virtual representations used for simulation, planning, validation and optimization.

Use as mechanism evidence, not as a fixed savings promise.

Strategy & research

McKinsey

2023

Strategy & research

Digital twins: The key to smart product development

McKinsey describes digital twins as a way to improve testing and validation, with development-time reductions for some users.

General digital twin evidence; not a guaranteed VC benchmark.

McKinsey

2024

Strategy & research

What is digital-twin technology?

McKinsey explains that digital twins can simulate real situations, support scenario planning and improve decisions.

General digital twin evidence; not a guaranteed VC benchmark.

McKinsey

2024

Strategy & research

Digital twins: The next frontier of factory optimization

McKinsey describes factory digital twins for what-if analysis, bottleneck detection and operational decision support.

General digital twin evidence; not a guaranteed VC benchmark.

2021

Strategy & research

Transfer Learning as an Enabler of the Intelligent Digital Twin

Maschler et al. describe testing before the physical system exists, speeding commissioning and reducing costly modifications.

Academic mechanism support; customer data still determines the result.

2024

Strategy & research

Unity 3D digital twin framework for industrial robots

A 2024 paper presents a Unity 3D-based digital twin framework for industrial robots with real-time visualization and control.

Academic mechanism support; customer data still determines the result.

IDTAStrategy & research

Industrial Digital Twin Association

IDTA positions the Industrial Digital Twin and Asset Administration Shell as key building blocks for standardized Industry 4.0 data infrastructure.

Industrial standardization context; not a savings benchmark.

Next layer

Extended value

Separate from core ROI

The value does not stop at commissioning

Once the VC model exists, it can also become a reusable asset for sales, training, documentation, service and new projects.

Digital model as a reusable asset

This part only shows potential beyond the main calculation. Value counts only when the customer actively selects a concrete reuse path.

1. Core project

First, prove the VC case

The main calculator owns the direct impact from Development, Test & FAT and SAT onsite.

2. Extended value

Then assess reuse

Select additional value streams only when there is a use case, history or a reasonable customer-specific assumption.

3. Evidence and caveats

A separate source area follows the map, so reuse value is not mixed with the core calculation's VC evidence.

Financial separation

0 optional value streams are included in this scenario.

Core VC impact

DKK 127,500

Optional additional value

DKK 0

Combined scenario

DKK 127,500

Reusable value around the digital model

Start with the model in the center. Choose a reuse path when the customer wants to estimate concrete additional value.

Core VC includedOptional reuse value

Digital model

VC asset

Evidence for extended reuse value

These sources relate to reusing the digital model in sales, training, documentation, service and future projects.

McKinseyPwC

IDTA

Phase	Hours without VC	Reduction with VC	Hours saved	Extra savings	Gross savings	of total
Development	300 h	20%	60 h	DKK 0	DKK 0	0%
Test & FAT	250 h	30%	75 h	DKK 45,000	DKK 45,000	35%
SAT onsite	120 h	20%	24 h	DKK 82,500	DKK 82,500	65%

Value stream	Status	Contribution
Sales & customer alignment	Not included	-
Marketing & interactive product demo	Not included	-
Training & onboarding	Not included	-
Documentation & knowledge reuse	Not included	-
Service & remote support	Not included	-
Future project reuse	Not included	-
Quality & rework risk	Not included	-
Operations & maintenance optimization	Not included	-

Build a customer-specific Virtual Commissioning business case

Adjust a few project assumptions, review the net effect and open the evidence layer only when the conversation needs it.

Project setup

You only change assumptions. Calculations run automatically.

0 of 4 filled

Customer / project

Machine / system

Currency

Average hourly rate

VC project cost

Development

60 h

DKK 0

Hours without VC

Reduction with VC: 20%

Test & FAT

75 h

DKK 45K

Hours without VC

Reduction with VC: 30%

Extra calendar weeks saved

Weekly cost (excl. hours)

Extra weekly saving = extra calendar weeks saved × weekly cost

Saved hours capture person-hours. Extra calendar weeks capture additional calendar impact. Do not include the same saving in both places.

SAT onsite

24 h

DKK 83K

Hours without VC

Reduction with VC: 20%

Extra calendar weeks saved

Weekly cost (excl. hours)

Extra weekly saving = extra calendar weeks saved × weekly cost

Saved hours capture person-hours. Extra calendar weeks capture additional calendar impact. Do not include the same saving in both places.

Hours saved

159 h

Gross savings

DKK 128K

VC cost

DKK 0

Net effect

DKK 128K

VC cost share

Net return

N/A

Biggest value driver: SAT onsite with 65% of savings

How this is calculated

Transparent formulas behind the result

Hours savedHours without VC × Reduction with VC

Value of saved hoursHours saved × Average hourly rate

Extra weekly savingExtra calendar weeks saved × Weekly cost

Phase savingValue of saved hours + Extra weekly saving

Gross savingSum of all phase savings

Net effectGross saving - VC project cost

Net return on VC costNet effect / VC project cost × 100

VC cost share of gross savingVC project cost / Gross saving × 100

Saved hours capture person-hours. Extra calendar weeks capture additional calendar impact. Do not include the same saving in both places.

Business impact

Process flow

Visualisation of savings distribution across phases

Development

Hours saved60 h

Gross savingsDKK 0

0% of total

Test & FAT

Hours saved75 h

Gross savingsDKK 45K

Extra savingsDKK 45K

35% of total

SAT onsite

Hours saved24 h

Gross savingsDKK 83K

Extra savingsDKK 83K

65% of total

Net effect

DKK 128K

Evidence for the core VC impact

Sources that support the mechanisms behind the main calculator's Development, Test & FAT and SAT onsite impact. No fixed savings or endorsement implied.

McKinsey

IDTA

Evidence for the core calculation

Use this panel when the customer wants to understand assumption ranges, industrial examples and references behind the direct VC calculation.

Assumption guidance

Defaults are in the upper expected range based on published industry data. The table shows the span from conservative to ambitious assumptions.

Input	Conservative	Expected	Ambitious	Note
Development reduction	10%	20%	30-35%	Use higher values only when early simulation meaningfully reduces engineering rework.
Test & FAT reduction	20%	30%	40-50%	Use higher values only when PLC, robot logic, sequences, interlocks and machine behavior are tested virtually before physical FAT.
SAT onsite reduction	10%	20%	30%	Use higher values only when major logic, sequence, robot, operator-flow or integration risks are validated before onsite work.
Extra FAT weeks saved	0-0.5	1	1-2	Only include calendar/test-floor savings not already counted as person-hours.
Extra SAT weeks saved	0-0.5	1-2	2-3	Only include onsite, travel, accommodation, delay or opportunity cost not already counted as person-hours.

If you have historical project data, use it as a starting point. For new project types, the 'Expected' column is a good default. Adjust toward conservative for lower complexity.

Sources behind the Virtual Commissioning impact

These sources support mechanisms such as earlier validation, realistic simulation, reduced FAT/SAT debugging and lower risk of late changes in the core project.

Virtual commissioning cases

Tecnomatix robotics programming and simulation

Siemens describes virtual commissioning and robotics simulation for validating manufacturing cells with automation and robot logic before physical commissioning.

Use as mechanism evidence, not as a fixed savings promise.

Virtual commissioning cases

Estun Automation virtual commissioning case

Siemens reports 30% reduced onsite commissioning time and 20% lower overall costs in a digital manufacturing and virtual commissioning case.

Use as a relevant industry case, not as a universal default.

Industrial simulation tools

RobotStudio Suite

ABB positions robot simulation and offline programming as a way to build, test and refine robot cells before physical commissioning.

Robot-specific evidence; do not use as a generic VC default.

Industrial simulation tools

Manufacturing and real-time 3D

Unity supports manufacturing use cases for virtual design review, robotics simulation, training and interactive digital twin experiences.

Use as mechanism evidence, not as a fixed savings promise.

Industrial simulation tools

Asset Transformer

Unity Asset Transformer helps convert and optimize CAD, BIM, mesh and point-cloud data for real-time 3D visualization.

Use as mechanism evidence, not as a fixed savings promise.

Industrial simulation tools

Industrial digital twins and simulation

NVIDIA frames digital twins as virtual representations used for simulation, planning, validation and optimization.

Use as mechanism evidence, not as a fixed savings promise.

Strategy & research

McKinsey

2023

Strategy & research

Digital twins: The key to smart product development

McKinsey describes digital twins as a way to improve testing and validation, with development-time reductions for some users.

General digital twin evidence; not a guaranteed VC benchmark.

McKinsey

2024

Strategy & research

What is digital-twin technology?

McKinsey explains that digital twins can simulate real situations, support scenario planning and improve decisions.

General digital twin evidence; not a guaranteed VC benchmark.

McKinsey

2024

Strategy & research

Digital twins: The next frontier of factory optimization

McKinsey describes factory digital twins for what-if analysis, bottleneck detection and operational decision support.

General digital twin evidence; not a guaranteed VC benchmark.

2021

Strategy & research

Transfer Learning as an Enabler of the Intelligent Digital Twin

Maschler et al. describe testing before the physical system exists, speeding commissioning and reducing costly modifications.

Academic mechanism support; customer data still determines the result.

2024

Strategy & research

Unity 3D digital twin framework for industrial robots

A 2024 paper presents a Unity 3D-based digital twin framework for industrial robots with real-time visualization and control.

Academic mechanism support; customer data still determines the result.

IDTAStrategy & research

Industrial Digital Twin Association

IDTA positions the Industrial Digital Twin and Asset Administration Shell as key building blocks for standardized Industry 4.0 data infrastructure.

Industrial standardization context; not a savings benchmark.

Next layer

Extended value

Separate from core ROI

The value does not stop at commissioning

Once the VC model exists, it can also become a reusable asset for sales, training, documentation, service and new projects.

Digital model as a reusable asset

This part only shows potential beyond the main calculation. Value counts only when the customer actively selects a concrete reuse path.

1. Core project

First, prove the VC case

The main calculator owns the direct impact from Development, Test & FAT and SAT onsite.

2. Extended value

Then assess reuse

Select additional value streams only when there is a use case, history or a reasonable customer-specific assumption.

3. Evidence and caveats

A separate source area follows the map, so reuse value is not mixed with the core calculation's VC evidence.

Financial separation

0 optional value streams are included in this scenario.

Core VC impact

DKK 127,500

Optional additional value

DKK 0

Combined scenario

DKK 127,500

Reusable value around the digital model

Start with the model in the center. Choose a reuse path when the customer wants to estimate concrete additional value.

Core VC includedOptional reuse value

Digital model

VC asset

Evidence for extended reuse value

These sources relate to reusing the digital model in sales, training, documentation, service and future projects.

McKinseyPwC

IDTA