Keyur B

Keyur B

March 23, 2023 9 minutes to read

What is virtual commissioning

What is virtual commissioning

The world of manufacturing and logistics is becoming more and more fast-paced, with companies facing intense pressure to stay ahead of the competition. To stay afloat, many organizations are turning to automation systems to streamline their processes. But with such sophisticated technology comes great responsibility – the task of getting these systems to work seamlessly can be a complex and challenging one.

Enter Virtual Commissioning, a game-changing solution for challenges in the manufacturing industry. With Virtual Commissioning, companies can save time and resources by testing and fixing any issues with the control software before it is even connected to the real system. This is made possible by utilizing Digital Twin modelling and virtual commissioning, which allows for testing, debugging, and validation to be done from the comfort of a computer. Imagine the time and effort that can be saved by catching any errors and fixing them before they even have a chance to cause problems on the factory floor. Virtual Commissioning can save nearly two-thirds of the commissioning time that would normally be spent fixing issues on site. By eliminating the need for on-site commissioning, companies can minimize downtime, reduce costs, and increase efficiency.

In order to streamline manufacturing processes and stay ahead of the curve, consider the power of Virtual Commissioning. With its ability to simplify and optimize the commissioning process, it’s the key to unlocking a world of opportunities for the business.

What is Virtual Commissioning?

Virtual commissioning takes the guesswork out of manufacturing by using cutting-edge simulation technology to design, install, and test automation systems before putting the actual hardware to use. Imagine being able to optimize a robot’s deployment, troubleshoot issues, and fine-tune performance, all without having to shut down your production line. That’s the magic of virtual commissioning.

At its core, virtual commissioning is powered by sophisticated simulation software. This software acts as a virtual sandbox where you can build, test, and refine your automation system to perfection. It includes virtual models of all the technologies you plan to use, as well as advanced algorithms that help you test every aspect of your system’s operation, so you can be confident in your setup before you go live.

Virtual Commissioning vs Traditional Machine Commissioning: A Comparison

The commissioning of new production equipment and manufacturing plants is a critical step in ensuring that the customer and vendor are on the same page in terms of specifications and requirements. This process involves the engineering, negotiation, and acceptance of a designed-to-fit production line. However, traditional commissioning can expose both parties to significant risk, as it involves the physical inspection and operation of prototypes or even the actual equipment.

Milestone reviews during commissioning often result in additional engineering investment or construction, adding to the cost and risk involved. This is where virtual commissioning comes in, offering a solution that minimizes risk and cost while maximizing efficiency.

Virtual commissioning leverages the power of 3D modelling to test the capabilities and functionality of equipment based on digital models, or digital twins, without the need for physical construction. This approach allows for simulation and evaluation of the entire production line, or even just a single assembly task, and provides an opportunity to identify potential improvements early on in the process.

While virtual commissioning is an attractive option, it may not fully fulfil the requirements of traditional machine commissioning if the planned equipment involves processes that cannot be reliably predicted by deterministic simulation and analysis, such as those that require human interaction. Without the presence of real machines, human-centric process issues can go undiscovered until it’s too late to resolve them cost-effectively.

The key to bridging the gap between virtual and traditional commissioning lies in finding ways to allow human interaction with the digital model in a similar manner to that of traditional commissioning, but in a virtual setting. This way, human-centric process issues can be identified and addressed before physical construction begins, reducing risk and increasing efficiency.

Industry 4.0 & Virtual Commissioning

Industry 4.0 is a term that has captured the imagination of the manufacturing world and beyond, marking a seismic shift in the way we approach production and automation. This fourth industrial revolution is all about harnessing the power of technology to create smarter, more efficient systems that can operate with minimal human intervention.

At the heart of Industry 4.0 lies the fusion of cutting-edge sensor technologies, internet connectivity, and artificial intelligence, allowing for the creation of “cyber-physical systems.” These systems have the ability to report on their conditions in real-time, respond to trends and optimize their performance, leading to a step-change in manufacturing capabilities that is reminiscent of the earlier revolutions of steam, electricity, and computerization.

However, the complexity of Industry 4.0 systems demands a new approach to their implementation and operation. Enter the digital twin and virtual commissioning. These two innovative processes are essential tools in the Industry 4.0 toolkit, providing a virtual replica of physical assets, processes, and systems, allowing manufacturers to simulate and optimize the entire lifecycle of their products, from design and development to operation and maintenance.

In short, Industry 4.0 represents a new era in manufacturing, one in which technology and human expertise combine to create systems that are smarter, more efficient, and more sustainable than ever before. The digital twin and virtual commissioning are two of the key drivers of this revolution, paving the way for a future in which manufacturing is truly transformed.

How does virtual commissioning work?

Virtual commissioning harnesses the power of sophisticated simulation technology to create a digital replica of the manufacturing system before it is physically implemented. The process involves three key elements: the digital model, controller code, and the development environment.

  • Digital Model: At the core of virtual commissioning is the creation of a digital twin or model of the entire manufacturing system. This digital model includes virtual representations of all the machinery, robots, conveyor belts, sensors, and other components that make up the automation system. The model is designed to replicate the physical system accurately, allowing engineers to test and analyze its behavior in a simulated environment.
  • Controller Code: The controller code is the software that governs the behavior of the manufacturing system. It consists of the control algorithms and logic that regulate the actions of the machinery and coordinate their interactions. During virtual commissioning, this controller code is integrated into the digital model, enabling engineers to assess how the system would function in reality and identify any potential issues or inefficiencies.
  • Development Environment: Virtual commissioning takes place within a specialized development environment that facilitates the creation, testing, and optimization of the digital model and controller code. This environment provides tools for engineers to interact with the simulation, run virtual tests, and make adjustments to the control software. Engineers can simulate various scenarios, evaluate different production parameters, and fine-tune the automation system’s performance.

Through this process, engineers can iteratively refine the digital model and controller code until they achieve an optimized and fully functional automation system. Virtual commissioning allows them to identify and rectify any design flaws, assess the system’s response to different inputs, and ensure its smooth operation, all without incurring the costs and risks associated with physical commissioning.

The Art of Digital Validation Through Virtual Commissioning

Bringing digital product concepts to life and revolutionizing the way manufacturing enterprises validate their products and processes, virtual commissioning is here to change the game. By leveraging cutting-edge virtual reality solutions, stakeholders can experience a virtual version of proposed equipment for commissioning and take their digital twin beyond managing CAD geometry and product data.

By eliminating the need for physical builds and in-person reviews, virtual commissioning supports efficient collaboration between product and manufacturing engineering teams, suppliers, pilot facilities, industrialization partners, and assembly line operations teams, reducing travel and ensuring a ‘first-time right’ start of production. Virtual exploration and validation of human-centric assembly cells and lines can help companies stay agile in managing changes and updates to their assembly lines, quickly adapting to changes in demand or available workforce. While virtual commissioning may not close every potential gap between conventional machine commissioning and a completely digital workflow, it is significantly closer to reality, offering a step-change in the manufacturing capabilities of companies.

A Closer Look at the Five Key Benefits of Virtual Commissioning

These are the unique benefits of virtual commissioning that sets it apart from traditional methods, providing a cost-effective, time-saving and risk-averse solution for automation testing and validation.

  • Streamlined Deployment: Virtual commissioning eliminates the need for time-consuming on-site activities, leading to a more efficient deployment process. This minimizes downtime and streamlines operations, resulting in significant time and cost savings.
  •  Safe Automation Testing: Simulating potential hazards in a virtual environment ensures safe automation testing. By identifying and resolving issues before deploying physical hardware, companies can prevent accidents and injuries that might occur during traditional physical commissioning. Moreover, limit cases that are impossible to test in reality can be examined virtually.
  •  Seamless Team Collaboration: Virtual commissioning facilitates better team collaboration by providing a platform for all members to view, understand, and contribute to the automation solution. Improved communication and shared access to simulations, such as with RoboDK for Web, eliminate misunderstandings and improve overall efficiency.
  •  Agile Adjustments: With virtual commissioning, companies have the flexibility to make changes or adjustments to their production process at any time. The simulator allows for quick testing of new ideas without disrupting real-life production, ensuring the automation solution is always up-to-date and responsive to changing requirements.
  •  Enhanced Understanding: Developing an automation solution in a virtual environment provides a deeper understanding of its functionality. Engineers can explore the technology’s capabilities and limitations within the simulation, allowing them to make better use of it in real-life scenarios. This knowledge empowers teams to optimize their automation systems for maximum efficiency and performance.

The Way Ahead

With advancements in technology, virtual commissioning is becoming more accessible and user-friendly, allowing more businesses to adopt it. Companies are also becoming more aware of the numerous benefits of virtual commissioning, such as improved operational efficiency, safer automation, better communication, flexibility to changes, and better understanding of solutions.

Virtual commissioning allows manufacturers to simulate the production process before investing in physical hardware, which minimizes the risk of errors and reduces downtime. With the ability to simulate the production process in a virtual environment, manufacturers can optimize their automation systems, ensuring that they are running at maximum efficiency. Virtual commissioning is becoming increasingly valuable as manufacturers are facing an ever-increasing need for flexible, efficient, and cost-effective production solutions. In the coming years, virtual commissioning is likely to play a key role in the digitalization of the manufacturing industry combining with AR solutions, helping businesses to streamline their processes, reduce costs, and remain competitive in an ever-evolving market.

Augmented Reality Applications On Factory Floor

Explore use cases of AR for shop floor operations

Download Ebook

FAQs

Virtual commissioning involves creating a digital model of the manufacturing system, including all components and control software, within a specialized simulation environment. Engineers interact with this model, testing and refining the automation system's behavior before physical implementation. This approach allows for identifying and resolving issues, optimizing performance, and ensuring smooth operation without the need for costly and time-consuming physical commissioning.

The key benefits of virtual commissioning include streamlined deployment, safe automation testing, seamless team collaboration, agile adjustments, and enhanced understanding of the automation system. These advantages lead to significant time and cost savings, improved efficiency, reduced downtime, better communication among teams, and the ability to quickly adapt to changes in production requirements.

Virtual commissioning eliminates the need for time-consuming on-site activities during traditional machine commissioning. By identifying and resolving issues in the digital model before physical implementation, companies avoid potential downtime and expensive fixes. This streamlined approach significantly reduces the time and costs associated with commissioning and helps businesses operate more efficiently.

Yes, virtual commissioning can improve production efficiency. By simulating and optimizing the manufacturing system in a virtual environment, engineers can identify and address inefficiencies, potential hazards, and bottlenecks. This knowledge enables companies to fine-tune their automation processes, leading to higher productivity and improved overall efficiency.

Virtual commissioning can benefit a wide range of industries that employ complex manufacturing systems, such as automotive, aerospace, pharmaceuticals, and consumer goods. However, its suitability may vary based on specific requirements and the complexity of the manufacturing processes. Industries that prioritize precision, quality, and efficiency can find virtual commissioning particularly valuable.
Keyur B

Keyur B

CEO, Founder of Plutomen

With more than 12+ years of experience in the world of enterprises, technology, and metaverse, Keyur Bhalavat is leading Plutomen to gain meaningful partnerships & to have a strong clientele network. He is one of the board members of GESIA (Gujarat IT Association Ahmedabad).

Recent Blog

Check out our latest blogs and news on all-things in Manufacturing.

9 Powerful Applications of Industry 4.0 Solutions 

According to a recent survey done by Deloitte, nearly 70% of manufacturing organizations have either started Industry 4.0 initiatives or are actively contemplating their adoption. The same study also showed that these businesses anticipate using Industry 4.0 technologies to enhance revenue by 22% over the following five years. These startling figures highlight how important it […]

July 19, 2023

Paperless Manufacturing: The Definitive Guide

In 2021, 408 million tons of paper was used. This is a massive amount of paper considering that to complete the paper demand of the US, 1 billion trees had to lose their life. Don’t you think it’s time to go paperless in everything you do today? When everyone from an individual to an industry […]

October 3, 2023

How to Train Manufacturing Operators: 7 Effective Ways

In today’s competitive world, having a highly skilled and efficient workforce is crucial for manufacturing industries to succeed. However, many manufacturing industries struggle with finding and retaining skilled operators, and even when they do, they often lack the proper training to maximize their potential. Training is not only crucial to ensure the safe and effective […]

October 4, 2023