Simulation to

Virtual Commissioning
 Simulation to Virtual Commissioning
Agenda

• DSI Overview
• Systems Analysis using Plant Simulation
• Skillet System
• Baggage Handling System

• Emulation/Virtual Commissioning
 Introduction
Welcome to DSI
 A full service engineering provider
 Private company founded in 1983
 Celebrating over 35 years of service
 Focused on long term client relationships
 Over 85% repeat client business
 Over 275 engineering & support personnel
 Strategic office locations to serve the global market place

 Farmington Hills, MI – Headquarters

 Windsor, Ontario

 Saltillo, Mexico
 Introduction
Welcome to DSI

Design Systems, Inc. - Providing Manufacturing Engineering

and Consulting services to the industrial, processing, and
manufacturing, as well as the warehouse and distribution
community.
Our core engineering disciplines include:
Mechanical & Conveyor Simulation Engineering
Electrical & Controls Paint Finishing
Manufacturing / Industrial Supply Chain Consulting
Program Management
 Services
Markets Served
Package & Parcel Handling
Heavy Truck
Heavy Equipment Manufacturers
Specialty Vehicles
Automotive Glass - Paper - Steel
Aerospace Pharmaceutical
Baggage Handling Powertrain
Food & Beverage Metal Stamping
Foundry
Government – Defense
Painting & Coating
Conveyor Manufacturing Tire Manufacturers
Construction & Installation Plastic & Resin
System Analysis Utilizing
Plant Simulation
 System Analysis
Experience

• Simulation experience spans more than 30 years

with a cumulative staff experience of more than
100 years
• Consists of DSI engineers from all engineering
disciplines
• Major Software Utilized
• Plant Simulation
• AutoMod
• Witness
 System Analysis
Simulation Benefits

The benefits of conducting a simulation analysis on your

system are numerous and include the following:
• Develop a thorough understanding of your system.
• Improve communication and system understanding across departments.
• Predict how existing system modifications will effect operations prior to
actually changing the system.
• Determine the “best” proposed system concept prior to making any capital
investment.
• Predict how volume or product mix changes will impact operations.
• Document your system in terms of process function, data parameters and
process flow.
 System Analysis
Simulation Benefits

Continued benefits of a simulation analysis:

• Simulation provides an animated 3D graphical representation of your
system.
• The simulation model is a living tool which accurately represents your
current/proposed operations and can be used to test “What If?” scenarios
for your system.
• A “user friendly interface” can be developed for the simulation model which
gives you the ability to use the model to test various scenarios.
 System Analysis
Approach

Our approach to a project involves the following steps:

• Develop a thorough understanding of the project
• Gather and validate data and assumptions
• Develop a simulation specification which documents the model framework
and data assumptions
• Construct a simulation model which accurately represents the system
• Validate the simulation results to “real world” performance of the actual
system
• Conduct analysis to understand the behavior of the system
• Report recommendations and solutions
 System Analysis
Plant Simulation
We have completed studies on a wide variety of systems ranging from small
isolated areas and work cells to full system studies and even complete facilities.
Examples of system types Design Systems has studied include but not limited to:
• Material Flow (Fork Trucks/Tow • Conveyor systems
Trains) o Power & Free systems
• Robotic Cells o EMS systems
• AGC/AGV System o Skillet systems
• ASRS o Skid systems
o Belt & Roller systems

How do we use Siemens Plant Simulation?

Design Systems is utilizing Plant Simulation for both Simulation Models/Analysis
and Emulation/Virtual Commissioning.
System Analysis
Skillet Line Example
 System Analysis
Utilization
The simulation model will be utilized to perform the
following analysis:
• Validate/Quantify system throughput
• Optimize number of skillets
• Identify bottlenecks
 System Analysis
Baggage Handling System Example
 System Analysis
Baggage Handling System Example

The simulation model was utilized to:

• Validate system throughput
• Provide customer with visualization of the system
• Optimize the number of AGC/carts
• Examine system control
• Determine operator utilization
• Identify bottlenecks
 Emulation/Virtual
Commissioning Utilizing
Plant Simulation
 Virtual Commissioning Services
Overview
• With Plant Simulation, we can drive the model
virtually via connection to a PLC, running the actual
program code, and validate the logic.
• Design Systems offers virtual commissioning services
to significantly reduce time and cost by providing off-
line testing of the control systems regardless of the
state of the hardware.
• Emulate before you Operate!
 Virtual Commissioning Services
Process

Process
• Review PLC program and identify I/O required to run Plant Simulation model
• Develop detailed model, including required field devices (proxes, photoeyes, etc.)
per design layout and I/O listing
• Set up the OPC server communication which serves as the interface between the
PLC and the Plant Simulation model
• Test the Plant Simulation model
• Verify PLC logic, HMI’s, and MES (alarms, graphics, part data, etc.)

DATA DATA

PLC OPC server Plant Simulation

 Virtual Commissioning Services
Inverted P&F Conveyor
DSI successfully completed virtual commissioning for a customer’s IPF
conveyor system validating the PLC program and Manufacturing Execution
System (MES)
 Virtual Commissioning Services
Challenges

• For virtual commissioning, it is important to have

completed PLC programs on-time to run the model.
• Determining if an open issue is caused by the PLC
program or the Plant Simulation logic.
• Due to limited experience with virtual commissioning
by our customers, the biggest challenge is
showcasing its value.
 Virtual Commissioning Services
Why Virtual Commissioning
• Testing the control system with a simulated model can be started as soon
as the control system is ready for debug.
(No waiting for installation of the physical hardware.)

Traditional Project Stages:

Panel Field
Engineering Field Install Virtual commissioning
Build Debug

SOP
Logic Validation
can reduce the time
(On-Site Testing)
required on-site by
Project Stages Utilizing Virtual Commissioning: completing logic
Panel validation off-site
Engineering Field Install Field

Build Debug
virtually
SOP

Logic Validation
(Off-Site Testing)
 Virtual Commissioning Services
Benefits
• Start-up and schedule risk mitigation
• Reduces control system development and debug time prior to installation so
development time is easier to manage
• Provides system testing in a lab environment without skilled trades required
• For maintenance personnel, provides an off-line tool for training and testing
of fault responses
• Reduced commissioning costs due to reduced systems validation time on the
plant floor
• Allows testing of complex product blends and production scenarios for
production personnel
 www.DSIDSC.com
Sales@DSIDSC.com
38799 West 12 Mile Road
Farmington Hills, Michigan 48331
P (248) 489-4300

Questions & Answers

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