Virtual Commissioning (VC) is revolutionizing industries by allowing businesses to thoroughly test and optimize production processes before physical implementation. Siemens leads this transformation with its advanced VC technology, delivering faster, safer, and higher quality commissioning. This article explores the unique advantages of Siemens VC and highlights successful case studies with Estun Automation and Wipro PARI, demonstrating its real-world impact. 

Siemens Virtual Commissioning

Siemens Virtual Commissioning
Source: Siemens Digital Industries Software 

How Siemens VC Stands Out 

Superior Capabilities 

  • Comprehensive Simulation: Siemens VC offers complete machine simulations, including software execution, to validate functions and speed up verification. It integrates physical and virtual controls, supporting HiL and physical machine incorporation, enhancing simulation fidelity and commissioning quality. 
  • Reusable Data Library: Siemens VC includes a vast reusable data library with components for various machine functions. This accelerates validation processes, ensuring consistency and accuracy across projects, and saves significant time. 

 Shortening Commissioning Time 

  • Reduce Time and Costs: Utilizing digital tools, Siemens Process Simulate significantly reduces commissioning time and costs, decreasing overall project duration and expenses. 
  • Increase Project Capacity: Streamlining operations allows businesses to handle more projects efficiently, boosting revenue potential. 

Digital Twin Integration 

  • Comprehensive Digitalization: Process Simulate enables the entire commissioning process to be digitalized within a digital twin, identifying and resolving issues at an earlier stage. 

Collaboration Enhancement 

  • Integrated Environment: Virtual commissioning fosters collaboration between engineering and control departments, providing a unified platform for early testing and mutual validation of work. 

Cost-Effective Concept Validation 

  • No-Cost Validation: Validate complete line designs, including mechanical components, robot programs, AGVs, and automation, in a 3D environment before physical commissioning, eliminating early-stage errors. 

Reduced Dependency on Physical Tryouts 

  • Virtual Debugging and Testing: Virtual debugging and testing of manufacturing systems diminish the need for physical tryouts, resolving issues before physical implementation. 

Virtual commissioning creates a shift in implementation behavior
Source: Siemens Digital Industries Software 

Case Studies 

Estun Automation 

Estun Automation overcame long design cycles and high hardware costs by implementing Siemens’ virtual commissioning technology. This streamlined their design and validation process for a battery and photovoltaic production line, cutting project costs by 20% and commissioning time by 30%. The use of virtual commissioning also improved collaboration and enhanced their digital twin capabilities. 



Wipro PARI

Wipro PARI drastically reduced commissioning time by 70% for an engine assembly line using Siemens’ virtual commissioning tools. This led to a 40-50% decrease in rework and improved process reliability early on. The company plans to expand its virtual commissioning capabilities due to the success of this implementation. 

 To Summarize 

  1. Siemens Virtual Commissioning offers robust machine simulations and a reusable data library, integrating physical and virtual controls for enhanced commissioning quality. 
  2. Siemens Process Simulate reduces commissioning time and costs, increases project capacity, and facilitates early issue resolution through digital twin integration. 
  3. Case studies at Estun Automation and Wipro PARI showcase significant cost reductions and efficiency improvements in production line commissioning, validating Siemens’ virtual commissioning technology‘s effectiveness. 

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