Operation and operating modes
Plant screens, manual functions and the automatic sequence are taught on the virtual plant.
Practise operating sequences
before production depends on them
Use the virtual commissioning model for operation, troubleshooting and restart.
New plants and changed sequences require practice. Yet the real machine is often only available shortly before the start of production, when training and ramp-up already compete for the same plant time.
The simulation model from virtual commissioning brings training forward. Operators, maintenance staff and commissioning engineers get to know operator screens, operating modes and fault patterns while the plant is still being assembled, and arrive at the real machine with practical experience.
Start now at no cost
In a free first conversation we clarify which model exists, how many people are to be trained and which fault cases are to be practised.
What is practised on the model
The depth of the training depends on the role, the plant and the scope of the model.
Start-up and restart
Staff start the plant and bring it back into operation after an interruption.
Faults and diagnostics
Agreed fault patterns are triggered, recognised and cleared without intervening in production.
Format and part changes
Changeovers are practised insofar as they are relevant for the plant.
Training on the model and on the real plant
A simulation model from virtual commissioning stays in operation as a training environment after the software test.
Operators, operating staff and maintenance staff learn plant functions and sequences while the real plant is still being assembled or is not available for training. On the model, faults can be triggered and restarts practised without intervening in running production.
On site, instruction on the actual system and its real characteristics follows. Training is thus spread over the time before and after the plant is assembled.
Before the start of production
Staff get to know the plant before the ramp-up
Operating sequences, faults and restarts practised on the model prepare staff for the real machine.
AiFrom a virtual commissioning project
Battery module production line of an automotive end customer
120
The models of 16 plants were used for operator training of 120 people in total.
The training ran across several shifts, groups of people and plant clusters. Staff got to know operation and sequences before the real plants were available for training.
How the training is created
Ai1
Define training cases
Trainers and operators choose the tasks on the basis of the specific plant.
Ai2
Prepare the training station
The training model and connected operating devices are set up.
Ai3
Training and reuse
The model then serves for training, variants, conversions and retests of changed software.
- Ai
4
Apply it on the machine
Trained staff operate the real plant and clear faults.
For engineers
Working with the virtual commissioning model yourself
Automation engineers, commissioning engineers and those responsible for simulation learn to use the handed-over model themselves.
This includes loading the right model version, connecting to the PLC and robot, starting and resetting scenarios and diagnosing connection faults. For later training, the model version has to match the plant; its maintenance is agreed with the customer.
Frequently asked questions
We are glad to answer your detailed questions in a personal conversation.
Are the content and dates of the training fixed?
Content and dates depend on your plant and the tasks of the participants. Programming courses can complement training on the model.
Who can take part?
Operator, operating and maintenance staff, commissioning engineers, PLC and robot programmers as well as new and experienced employees who are getting to know a new plant.
Does the training need its own model?
The model from virtual commissioning is used. If none exists yet, we clarify which model scope the training requires.
Further industry solutions
Every industry has its particularities. That calls for a reliable partner who knows the requirements and delivers suitable solutions.
First conversation
Arrange a free first conversation
Describe your task. We agree a date and discuss the possible project scope.
Ai1
You request an appointment
Ai2
We discuss your requirements
Ai3
You receive a quotation for the agreed scope
Tobias KuckBusiness Development ManagerTakes up new projects, coordinates offers and accompanies the cooperation from the first enquiry.
Free first conversation
Describe your task in the contact form. We come back with a proposed date.
Arrange a first conversationBooking calendar
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Not quite what you need?
Discover further suitable services.
Virtual commissioning
Test PLC and robot programs on the digital plant model before real commissioning begins.
On-site commissioning
We bring software, peripherals and real sequences together, from the I/O check to the ramp-up.
PLC programming, HMI and SCADA
Connect sequence control, operation and diagnostics in one coordinated automation concept.