The buzz around Industry 4.0 and digitalization is undeniable. But beyond the hype, what practical steps can manufacturers and operations take to optimize processes and transform automation projects? The answer lies in embracing cutting-edge technologies like simulation and virtual commissioning.
Last year, at the Realize Live event, experts Tengyuan Zhang, Vice President, Technology at Longterm Technology Services, and Colm Gavin, Portfolio Development Manager at Siemens Digital Industries Software, provided an in-depth look at how virtual commissioning with advanced features is revolutionizing the automation industry. This blog marks the first part of a six-part series, where we’ll dive into the fundamentals of virtual commissioning, its growing importance in the industry, and the value it brings to manufacturers across the globe. We’ll also explore how Longterm Technology Services is supporting this digital transformation and helping companies navigate these technological advances.
Watch the presentation video here to see firsthand how virtual commissioning is transforming the industry, as well as the challenges and benefits that come with this digital evolution.
What is Virtual Commissioning?
Virtual commissioning is a process where manufacturers use a virtual model of their automation system to simulate and validate control logic, electrical behavior, and mechanical movement before deploying the system in the physical world. This process is conducted using digital tools and technologies that replicate real-world conditions, allowing engineers to troubleshoot, optimize, and fine-tune their systems virtually, all before any physical production begins.
If you’re new to virtual commissioning, there’s a simplified way to understanding the process – think of this analogy in comparison: just as pilots use flight simulators to practice flying and troubleshoot potential issues before operating a real aircraft, engineers use virtual commissioning to test and optimize automated production systems before physically building them. You may even be familiar with the more basic flight simulators you’ll find readily available in today’s gaming systems. Aside from how those systems are created (which we can dive down an entire design rabbit hole separate from this blog), the comparison of flight simulation and virtual commissioning remains parallel.
Industry Trends Driving Virtual Commissioning Adoption
At the Realize Live event, Gavin highlighted several key industry trends that are accelerating the adoption of virtual commissioning in manufacturing. These trends reflect the growing need for companies to embrace digital technologies to remain competitive and meet evolving customer demands:
- Sustainability and Net Zero Goals: In today’s manufacturing environment, sustainability is becoming a major focus. Manufacturers are striving to reduce their carbon footprint and minimize energy consumption. It helps companies design more efficient systems, identify energy waste, and improve resource management by optimizing their operations virtually before implementation.
- Individualized Production: The rise of mass customization has made production systems more complex. Consumers now demand personalized products, and manufacturing processes must be adaptable to these needs. It supports this shift by enabling manufacturers to simulate flexible, scalable production lines that can quickly accommodate changing product specifications and volumes.
- Digitalization & the Rise of the Digital Twin: The growing importance of digital twins-virtual representations of physical systems – have been a game-changer in manufacturing. Digital twins allow manufacturers to replicate their assets, simulate different operating scenarios, and optimize processes before making any physical changes to machinery or production systems. As industries increasingly require digital twins, virtual commissioning plays a critical role in ensuring the accuracy of these models.
- Labor Market Challenges: With a growing shortage of skilled workers, the need for automated systems and advanced training solutions has never been more pressing. It allows companies to create realistic training environments where operators can gain hands-on experience in a risk-free virtual setting, building their expertise and reducing human error.
As we’ve seen, virtual commissioning is transforming the way manufacturers approach automation projects, offering significant benefits in terms of time, cost, and efficiency. In this first part of our series, we’ve laid the groundwork for understanding this powerful tool and its growing importance in the industry.
In our next installment, we’ll take a closer look at the value of virtual commissioning in manufacturing. We’ll dive deeper into how it accelerates time to market, improves quality, enhances team collaboration, and provides critical training opportunities. Stay tuned as we explore how virtual commissioning can truly revolutionize the manufacturing process and drive greater efficiency across industries.
We’re excited to continue this journey with you – see you in part two!
