Successful plant conversion: A BEST PRACTICE EXAMPLE for successful virtual commissioning
The largest plant conversion in F.EE's history has been successfully completed at a leading car manufacturer - an impressive example of how virtual commissioning (VIBN) is revolutionising automation projects.
In a record-breaking time frame of less than four weeks, the F.EE team managed to hand over a complex infrastructure ready for operation:
- 15 conveyor technology control systems with approx. 1,000 conveyor elements
- 5 high-bay warehouses, each with 280 car body bays
- 7 process control systems
Particularly noteworthy: F.EE was able to leave the construction site after just two weeks of the ramp-up phase, as the systems had reached full availability – a time frame that would be almost unthinkable with conventional commissioning.
fe.screen-sim: The digital foundation for smooth commissioning
The key to this success lay in virtual commissioning with fe.screen-sim. Using a digital twin, the software made it possible to simulate all workflows and processes in advance:
- Firstly, the individual systems were tested virtually in manual and automatic mode.
- The safety matrix was checked and optimised.
- After successful acceptance of the individual systems, the network simulation followed.
- All required operating modes in normal operation and special sequences (such as full/empty buffer) were tested.
- Finally, the overall acceptance of the virtual commissioning was carried out by the end customer.
- The system training of the maintenance and production staff was carried out on the virtual model in advance. In addition to the normal processes and system operation, it was possible to run through and analyse error scenarios that would be difficult to implement in the real system environment.
This multi-stage virtual safeguarding works in a similar way to a flight simulator for pilots - errors can be recognised and rectified in a risk-free environment before they occur in real production.
The successful implementation at this car manufacturer impressively demonstrates how modern digitalisation tools such as fe.screen-sim can not only optimise technical processes, but also create significant time and cost benefits for car manufacturers and their suppliers.
Your personal contact person – for more clearness
You are a project or department manager and are faced with the question of how to set up a digital twin for your project? We would be happy to talk to you personally about your requirements, the time frame, the possible project approach and give you an initial cost estimate.