AI/ML 
Software Development 
Digital Twin and Virtual Commissioning in Production Line Modernization
Client
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.
Challenge
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.
Another challenge was ensuring that the digital model accurately reflected the real-world interactions between devices and the sequence of production operations. Verifying the PLC code alone is not enough to assess how the entire production line will behave. It is also essential to test how the controllers respond to signals from connected devices and whether individual sequences run as intended.
The more accurately the simulation environment replicates the behavior of the physical production line, the more potential issues can be identified before deployment in the production environment.
Solution
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.
Preparing the simulation environment requires accurately modeling how individual devices operate and interact with one another. This makes it possible to analyze how the production line responds to signals generated by PLC programs without having to perform all tests on the physical equipment.
The model allows engineers to verify whether the different components of the process work together as intended and whether the programmed control sequences follow the expected sequence of production operations.
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.
Virtual commissioning makes it possible to verify how PLC programs perform under different operating scenarios before they are deployed on the physical production line. Testing includes analyzing the sequence of operations, the system’s response to input signals, and the interaction between individual devices.
The simulation environment also allows engineers to test situations in which the process deviates from its normal sequence, for example, due to an incorrect signal or an unexpected device response. This helps identify issues in the control logic and make necessary adjustments before physical commissioning begins.
Once the PLC programs and test scenarios have been validated, the project can move to the next implementation stage with previously verified control logic, reducing the need for modifications directly on the production line.
Control Program Updates
We updated the production line control programs to meet new operational requirements and incorporate the results of the simulations.
Using the Digital Twin environment, we were able to validate the modifications before deploying them to the physical equipment. This allowed us to verify the control sequences and identify potential issues arising from interactions between different system components.
The test results provided a basis for further adjustments to the PLC software, reducing the need for modifications directly on the production line during commissioning.
Documentation and Reporting
We provided detailed progress reporting and prepared comprehensive technical documentation to support long-term maintainability and future system development.
Results
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.
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Jakub Orczyk
Member of the Management Board/ Sales Director VM.PL
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