Virtual Commissioning Using Plant Simulation: Transforming Manufacturing Optimization

 Introduction to Virtual Commissioning and Plant Simulation

Virtual commissioning is a process that allows companies to simulate and test their automation systems in a virtual environment before actual deployment on the factory floor. This method reduces commissioning time, minimizes risks, and offers a way to detect potential errors early in the design phase, enabling companies to avoid costly rework.

Siemens’ Plant Simulation, part of the Tecnomatix suite, provides a sophisticated environment for this process. It allows for the modeling of complex production systems, the validation of control logic, and the optimization of material flow, all within a simulated digital twin of a real-world system. Tecnomatix Plant Simulation not only improves the accuracy of design but also allows for continuous system optimization by collecting performance data from the virtual models and applying insights to real production systems.

This article is based on material presented during a webinar hosted by Siemens, exploring how virtual commissioning is reshaping manufacturing processes through advanced simulation tools like Plant Simulation.

Typical Challenges Addressed by Plant Simulation

During the webinar, some key challenges commonly faced by customers were highlighted, including:

• Detecting process interdependencies
• Increasing system flexibility
• Reducing the physical footprint of manufacturing lines
• Lowering capital expenses
• Making data-driven decisions
• Optimizing throughput and reducing work-in-progress inventory

Image courtesy: Siemens Digital Inudtries Software

Through virtual commissioning, Siemens Plant Simulation addresses these challenges by providing a dynamic and realistic representation of factory systems, enabling what-if scenarios, and helping users optimize control strategies.

Simulation at Every Level: Siemens' Ecosystem

Siemens showcased how Plant Simulation fits into a larger ecosystem of digital tools that support automation and process simulation across various stages of production. These tools include:

• PLCSIM Advanced and WinCC for automation and human-machine interface (HMI) testing
• SIMIT for simulating process behaviors and validating hardware-in-the-loop and software-in-the-loop scenarios
• Simcenter Amesim and NX Mechatronic Concept Designer for machine and robotic cell simulation

By integrating these platforms, Siemens provides a seamless environment for engineers to design, validate, and optimize both the digital twin of production lines and the real-world systems.

Practical Use Cases of Virtual Commissioning

On a use case involving the simulation of a material flow system and the validation of PLC (Programmable Logic Controller) code using PLCSIM Advanced. The process included:

1. Layout validation and optimization of material flow
2. Validation of PLC automation code before deployment
3. Risk-free testing in a virtual environment
4. Operator training on workflow and HMI using the simulated models

By validating these elements in a virtual environment, Siemens' Plant Simulation allowed for a streamlined process from design to deployment, significantly reducing on-site commissioning time and risk.

Goals of a Simulation Study: AGV System Evaluation

The webinar also discussed a case study focused on evaluating an Automated Guided Vehicle (AGV) transport system for a factory. The study aimed to:

• Understand the requirements of the AGV system
• Assess its behavior within the factory environment
• Determine which of four AGV models provided the best value in terms of performance and future scalability

Simulation provided valuable insights into the number of AGVs required and the best model to purchase based on a detailed analysis of performance data.

Benefits of Virtual Commissioning

Virtual commissioning provides multiple benefits for manufacturers:

• Reduced commissioning time: Testing and validating automation systems in a virtual environment significantly cuts the time needed for physical commissioning on the factory floor.
• Improved system efficiency: Simulations allow for the optimization of material flow and automation control, enhancing overall system performance.
• Lower risk: Risk-free testing in a digital environment helps prevent costly errors and ensures systems run as expected once deployed.
• Operator training: Virtual models provide a realistic environment for training operators in handling machinery and software, improving safety and proficiency.

One notable use case involves the commissioning of automated parking garages, where Plant Simulation helped validate system throughput and improve operational efficiency. This led to reduced on-site commissioning time and ensured that the system met performance expectations.

Virtual Commissioning Portfolio and Future Outlook

Siemens offers an extensive portfolio for virtual commissioning, including tools like Mechatronic Concept Designer, Process Simulate, and Plant Simulation. Together, these tools form a comprehensive solution for manufacturers to simulate entire production systems, from individual machines to entire plants. This portfolio supports Siemens' vision of a fully integrated digital twin across product design, production, and performance optimization.

Virtual commissioning using Plant Simulation is transforming the manufacturing industry by allowing companies to test and optimize their systems in a digital environment. Siemens' suite of digital tools, including Tecnomatix and PLCSIM Advanced, enables risk-free validation of processes, reduces capital expenditure, and supports continuous improvement. For companies looking to embrace Industry 4.0, virtual commissioning offers a powerful tool for optimizing automation, reducing downtime, and ensuring long-term operational success.

For more information or a 30-day free trial of Siemens’ Plant Simulation, visit Siemens Trials.