Smaller companies often do not use virtual commissioning in engineering, or only in isolated cases. This is because it is difficult to quantify the actual benefits of these technologies. However, a closer look quickly reveals the immense savings that can be made in all areas – sometimes several million euros a year.
As already mentioned in the blog posts on improving productivity and quality, the use of virtual commissioning opens up huge potential. This also applies to the time factor.
As part of a case study, machineering worked with a manufacturer of modular machines to determine the potential that can be exploited through the sensible use of virtual commissioning. Certain key figures were determined and compared before and after the implementation of iPhysics.
It was found that the consistent use of iPhysics in all relevant areas of the company resulted in a significant reduction in overall development time. The stabilization of the actual commissioning could also sustainably improve on-time delivery. In this specific case, this resulted in savings of EUR 191 thousand, mainly due to fewer contractual penalties resulting from missed delivery deadlines.
But where exactly is the potential?
The use of simulation software for virtual commissioning enables more efficient work. PLC programming in particular can be brought forward significantly thanks to parallel engineering. This reduces the lead time in real commissioning by up to 70 percent and the overall development time considerably.
Early testing during virtual commissioning in particular significantly reduces the time and effort required for troubleshooting and rectification. Errors can be found and corrected up to 70 percent faster.
The fact that the machine is delivered to the customer in an almost optimal condition also reduces the time required for commissioning at the customer’s premises. This means that employees can handle significantly more projects in the same amount of time.
What probably leads to the greatest savings is the fact that the throughput time is reduced by a total of 21%. This significantly improves on-time delivery and adherence to promised delivery times. Additional costs due to contractual penalties are eliminated and the customer is more satisfied. Punctual delivery of high-quality machines ensures a significant improvement in reputation. Customers are happy to return.
