Virtual Commissioning

Virtual Commissioning covers the use of simulation to plan, design, test, and install production systems

How to Get Started with Virtual Commissioning

The value-added benefits are clear. But many organizations don’t know where to start when it comes to virtual commissioning. The implementation process is complex; it’s more than downloading a piece of software and expecting staff to master it immediately. Reaping the full rewards of virtual commissioning requires a measured and staged approach.

Virtual Commissioning: Making the Case

Virtual commissioning promises a lot of value. Engineers can explore various alternatives while developing production systems. This tech-led initiative can save engineers vast amounts of time. Yet, that doesn’t mean a company’s chief financial officer is going to approve the financial investment that virtual commissioning requires.
What does a good cost justification look like?

Virtual Commissioning in Germany

Today, powerful modeling tools and compatible information standards make virtual commissioning accessible to all manufacturers. This article summarizes the state of the art in virtual commissioning, much of it developed by German researchers.

Virtual Commissioning in the Packaging Industry

Many companies want to upgrade commissioning processes with new technology, to increase efficiency and help gain or maintain their competitive edge. Learn how one packaging company has used virtual commissioning to support their digital transformation.

The Blurring Line between Virtual Commissioning and Digital Twins

The lines are blurring between virtual commissioning and digital twins. In this article, we’ll discuss each of these simulation techniques, when and how they are implemented and the impact of virtual commissioning and digital twin’s on today’s production systems.

MBSE and Virtual Commissioning: Do the Two Intersect?

The engineers who design production systems are not strangers to complexity. This raises the question: Can systems engineering be applied to the development of production systems? Let’s explore how, by discussing systems engineering and model-based system engineering.

The Digital Thread: Is It Applicable to Virtual Commissioning?

Digitization is complicated. In this post, we’ll explain and examine the emerging Digital Thread concept, investigate where the Digital Thread intersects virtual commissioning, the impact this concept has on organizations, and the opportunities a Digital Thread can bring to businesses.


A digital twin of a production system feeds production line sensor data into a simulation of the production line. You can then measure virtual sensors and capture virtual sensor data off of the simulation. When you combine that with the physical sensor data, you have a richer view into what is actually happening in the production system overall. In this post, Chad Jackson discusses the value of running virtual and physical sensors together.

Digital Twins of production systems. 1D? 3D? What is the best fit?

Commissioning production systems is no easy task. The effort is complex. The schedule is short. Everyone wants to minimize downtime in facilities and plants. Getting a head start on commissioning through virtual methods instead of waiting for physical hardware is a step in the right direction. However, when it comes to the tactics of virtual commissioning, there are multiple options. Some organizations use 1D simulation process models. Others leverage detailed 3D designs with animations. Yet others use combinations of these two approaches. In this post, we’ll take a look at each, identifying the advantages and disadvantages of these different methods.