Digital Twin and Virtual Commissioning in Production Line Modernization

Scania is a global manufacturer of trucks, buses, and engines, recognized for high-quality production and continuous optimization of industrial processes. In response to increasing operational demands and the need to modernize its automation infrastructure, the company decided to implement the Digital Twin concept and carry out virtual commissioning of its production lines.

The objective was to minimize downtime risk and improve the efficiency of implementing operational changes.

Modernizing active production lines in the automotive industry involves significant operational risk. Any change to control systems can impact production continuity, product quality, and delivery schedules.

Scania required a solution that would enable:

• creation of a Digital Twin accurately replicating real production processes,
• execution of Virtual Commissioning of automation systems prior to physical deployment,
• updating PLC control programs in line with new operational requirements,
• reducing testing performed directly on the production line,
• minimizing the risk of downtime during implementation.

Ensuring high simulation accuracy and full consistency between the virtual environment and the real production infrastructure was critical.

The modernization project was executed based on the Digital Twin and Virtual Commissioning methodology.

Digital Twin Development

We created a digital model of the production lines that:

• replicates real production processes,
• simulates PLC control logic,
• enables testing of production scenarios,
• allows analysis of system behavior under various operational conditions.

The Digital Twin became a virtual testing environment for planned changes.

Virtual Commissioning

The Digital Twin became a virtual testing environment for planned changes.

• testing of updated PLC programs prior to physical implementation,
• verification of control logic and process sequences,
• identification of potential errors and bottlenecks,
• reduction of tests requiring production downtime.

Control Program Updates

We updated the production line control programs, aligning them with new operational requirements and simulation results.

Documentation and Reporting

We provided detailed progress reporting and prepared comprehensive technical documentation to support long-term maintainability and future system development.

The project delivered significant operational benefits for Scania:

• successful implementation of the Digital Twin concept within a production environment,
• execution of Virtual Commissioning, reducing the need for physical testing,
• reduced risk of downtime during production line modernization,
• improved production processes through early validation of changes,
• increased implementation efficiency and greater predictability of outcomes,
• precise documentation supporting system stability and further optimization.

The project enabled controlled and secure modernization of production lines in alignment with operational objectives, while establishing a strong foundation for further digitalization in the spirit of Industry 4.0.