Virtual Commissioning of Production Lines

Clients appreciate the ability to verify designs for existing lines without halting production – simulations allow avoiding up to 80% of implementation errors during modifications.

Reduction of expenses for physical prototypes and hardware tests thanks to digital simulations of mechanical and electronic processes.

Minimizing the costs of subsequent modifications through early detection of logistical and technological errors.

MDP ensures full compatibility with:

• PLC controllers
• SCADA/MES systems
• Industrial robots (program testing and cycle time optimization)

Is It Worth It?

Virtual production line commissioning enables companies to increase their market competitiveness, improve operational efficiency, and reduce costs associated with implementing new production lines.

Quality and Efficiency Improvement

Accurate simulation: Allows precise modeling of production line behavior, translating into better final product quality.
Cost reduction: Avoids costly physical modifications to production lines that might be required after deployment.

Time and Cost Savings

Shortened implementation time: Virtual testing accelerates the deployment process of new production lines, reducing the time required for physical testing.

Cost reduction: Avoids costly physical modifications to production lines that might be required after deployment.

Production Process Optimization

Simulation and testing: Allows virtual testing of various production line configurations, enabling the identification and resolution of potential issues before physical implementation.
Risk reduction: Minimizes the risk of failures and downtime through early error detection in the design.

Personnel Training

Virtual training environments: Allow employees to be trained in a simulated environment, reducing the risk of errors made by untrained personnel.

Increased Flexibility

Rapid adaptation: Virtual production lines enable swift process modifications in response to market or technological changes.

Production System Modeling

Digital Twin Precision
Creating accurate 3D models requires specialized software (NX, SolidWorks) and advanced engineering expertise. Even a 5% discrepancy between the model and the physical system can invalidate simulation results.

Computational Constraints
Simulating complex processes involving robots and vision systems requires:

• High-performance workstations with multi-core processors
• Specialized GPU cards for real-time rendering

• High-IOPS storage systems for discrete-event simulations

Integration with Existing Infrastructure

Protocol Compatibility
Connecting the virtual environment with physical PLC controllers often reveals discrepancies in

• Communication standard implementations (PROFINET vs. EtherCAT)

• Firmware versions

• Industrial network configurations

Data Synchronization
Manual model updates during technical documentation changes lead to:

• 15–20% time loss in projects
• Risk of using outdated parameters in simulations

Implementation Process Management

Skill and Training Costs
Training teams in:

• Advanced features of simulation software
• Digital Twin methodology
• Interpretation of simulation results
   
  Can consume up to 30% of the project budget in the first year.

Cross-Department Coordination
Discrepancies in:

• CAD/CAE data formats
• PLC programming environments
• Technical documentation
  Result in an average of 2–3 revision iterations during the testing phase.

Technological Limitations

Human Factor Simulation
Virtual environments do not fully account for:

• Assembly errors (e.g., reversed sensor polarity)
• Manual operator adjustments
• Environmental impacts on sensors

Dynamic Requirement Changes
Modifications to production assumptions during the project require:

• Re-validation of the entire model
• HMI interface updates
• Review of test strategies