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Checklist for introducing Virtual Commissioning in your company.

As an additive and virtual commissioning smart expert partner for Siemens Industry Software in the UK & Ireland market, Kaizen PLM help companies enhance their product development and manufacturing capability. . Here’s a little more information on virtual commissioning and how to get started.

What is virtual commissioning?

The traditional commissioning process involves physically assembling the components of a system, such as a production line or an automated machine, and then testing its performance in a real-world environment.

However, this process can be time-consuming, costly, and potentially risky if issues arise during the actual commissioning phase.

In contrast, virtual commissioning leverages computer-aided simulations to create a virtual model of the entire system or individual components. This digital representation incorporates the behaviour and interactions of the various elements, including robots, sensors, actuators, controllers, and other machinery involved in the process. Engineers can then run tests, conduct simulations, and assess the system's performance under different scenarios without the need for physical prototypes.

What are the benefits of virtual commissioning?

The benefits of virtual commissioning include:

Early detection of design flaws: By simulating the system beforehand, engineers can identify and resolve design issues before physical implementation, reducing the need for expensive and time-consuming changes later in the process.

Risk reduction: Virtual commissioning allows for the testing of safety-critical systems in a controlled environment, minimizing the risk of accidents or hazardous situations during physical commissioning.

Time and cost savings: The virtual approach reduces the time needed for physical commissioning, leading to faster deployment and cost savings related to assembly, testing, and potential rework.

Training and operator familiarisation: Virtual commissioning can be used to train operators and maintenance personnel in a risk-free environment, enhancing their skills and confidence when operating the real system.

System optimisation: Engineers can fine-tune the system's performance and efficiency through simulations, leading to better overall operation and productivity.

What’s the difference between Virtual Commissioning and Digital Twins?

The main difference between Virtual Commissioning and Digital Twins lies in their purpose and focus. Virtual Commissioning is primarily concerned with simulating and validating the functionality of a system before implementation, while Digital Twins focus on creating ongoing virtual replicas of real-world assets for monitoring, analysis, and optimisation purposes throughout their operational lifecycle. Both concepts can complement each other in certain scenarios, where the insights gained from a Digital Twin might inform the virtual commissioning process for future improvements.

Checklist: for adding Virtual Commissioning to your Company processes

When you think that virtual commissioning might be worth it for you, here are some things to think about and answer before deciding:

  • How often do you wait for your robots, machines and manufacturing equipment to be available for testing your programs?

  • Have you ever lost a project because your price was too high, or the risk of the project was too high?

  • Do you waste a good part of your margin because the commissioning phase takes much longer than expected?

Learn more about Virtual Commissioning:

Contact us to get started with Virtual Commissioning

The implementation process can be complex; it’s more than downloading a piece of software and expecting staff to master it immediately! Reaping the full rewards of virtual commissioning requires a measured and staged approach. It takes patience and planning to guarantee a return on investment from this emerging and productive technology. But that where Kaizen come in, we do it all for you!

If you want to learn how virtual commissioning software enables your engineering team to reduce the time to market, lower costs, and build more flexible, multi-purpose machinery, why not book a discovery call with us.

Kaizen PLM

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