Overcoming Challenges in Commissioning: Insights from Dr. Tengyuan Zhang
Insights

Overcoming Challenges in Commissioning: Insights from Dr. Tengyuan Zhang

In Part 4 of our blog series, we discussed the importance of bridging the gap between virtual models and real-world manufacturing systems. Ensuring accurate virtual representations is crucial to prevent costly errors during commissioning. But what challenges do manufacturers face when bringing these virtual models to life? 

In Part 5, we’re shifting our focus to the real-world challenges faced during the commissioning phase. Our Vice President of Technology, Tengyuan Zhang, shares his insights on these hurdles, drawing from his extensive experience with customers in the automation industry. 

Unpacking the Challenges in Commissioning 

Commissioning is a critical phase in manufacturing where the mechanical, control, and robotic systems come together to ensure seamless operation. However, as Tengyuan notes, this process is often riddled with unexpected challenges:

  • Efforts for Real Commissioning: The process is inherently complex and time-consuming. For example, troubleshooting automation logic on a physical production line can take weeks, as engineers must repeatedly test, adjust PLC code, and resolve mechanical or electrical integration issues—all while minimizing downtime. 
  • Limited Parallel Testing Capacity: Teams often have to wait their turn, hindering efficiency. For example, when only one physical prototype or test system is available, engineers must work sequentially – mechanical teams may need to finalize hardware before controls engineers can validate PLC logic, leading to bottlenecks and extended development timelines. 
  • Unexpected Errors: Surprises are common, leading to delays and additional work. 
  • Potential Damage to Equipment: Collisions and malfunctions can damage hardware, requiring replacements. 
  • Limited Testing of Sequences and Recipes: Real-world testing is often constrained. For example, in a physical commissioning environment, testing all possible production sequences and recipe variations can be difficult due to time restrictions and limited access to machinery. Engineers may only be able to validate a subset of scenarios, increasing the risk of unexpected issues during production. 
  • Validation/Commissioning Time and Costs: These phases can consume a significant portion of project timelines. 
  • High Uncertainty Period: The unpredictable nature of commissioning can lead to significant delays and resource constraints. 
  • Resource Constraints: Delays in one project can impact subsequent projects due to resource bottlenecks.

As Tengyuan emphasized, these challenges not only impact timelines but also affect overall project costs and resource availability. For example, delays in one project can create a domino effect, disrupting schedules for upcoming projects and straining workforce allocation. 

The Hidden Costs of Commissioning Delays 

Tengyuan shared a striking insight: on average, 25% of the total project time is spent on testing and commissioning. This figure does not even account for potential delays due to equipment shortages or reordering damaged parts. When unforeseen complications occur, this percentage can soar to 50% or more, leading to significant budget overruns. 

Process Simulate Virtual Commissioning Validation/Commissioning Time and Costs

Validation/Commissioning Time and Costs 

 These delays also trigger resource bottlenecks, where teams are stuck troubleshooting one project, leaving insufficient capacity for new initiatives. This is particularly challenging for manufacturers who rely on tight schedules to meet customer demands. 

  The Path Forward: Addressing Commissioning Challenges 

While these challenges seem daunting, there are effective strategies to overcome them:

  • Virtual Commissioning: As discussed in Part 4, leveraging virtual models can help identify errors early, reducing the risk of unexpected issues during physical commissioning. 
  • Continuous Validation: Keeping virtual and physical systems synchronized through continuous validation ensures accuracy and minimizes discrepancies. 
  • Parallel Testing Capacity: By integrating virtual commissioning, manufacturers can increase their capacity for parallel testing, significantly reducing wait times and resource constraints. 
  • Proactive Risk Management: Identifying potential failure points during the simulation phase allows teams to address them proactively, reducing the likelihood of equipment damage or costly delays.

Learn from the Experts: Watch the Realize Live Session 

Don’t miss the accompanying video from last year’s Seimens’ Realize Live event, where Tengyuan Zhang shared first-hand experiences and strategies for overcoming these commissioning challenges. He discusses real-world scenarios and solutions that have helped manufacturers minimize risks, reduce costs, and optimize timelines. 

Watch Now

Looking Ahead: Driving Innovation in Manufacturing 

Commissioning challenges may be complex, but with the right strategies and tools, manufacturers can navigate them effectively. Virtual commissioning and continuous validation pave the way for a more efficient and reliable manufacturing process. 

Stay tuned for the final installment of our series, where we see Virtual commissioning in action with different scenarios, and proven successes of Process Simulate. 

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Detroit, Michigan | June 2–5, 2025
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