Digital Simulation & Virtual Commissioning

Digital Simulation & Virtual Commissioning

DiFACTO provides digital simulation and virtual commissioning services that validate automation systems before installation—reducing risk, minimizing downtime, and accelerating deployment. By testing systems in a virtual environment, manufacturers gain confidence that automation will perform as expected in production.

Overview

Digital simulation and virtual commissioning create a digital representation of automation systems, allowing logic, motion, and process interactions to be tested before physical equipment is built or installed. DiFACTO leverages these tools to identify issues early, optimize system performance, and streamline on-site commissioning.

Our approach reduces costly rework and shortens time to production.

Capabilities & Services

• Automation system digital simulation
• Virtual commissioning of robotic and control systems
• Offline robot programming and validation
• PLC and controls logic testing
• Cycle time and throughput analysis
• Collision detection and motion optimization
• Integration with digital twins and production models

Key Benefits

• Reduced Commissioning Risk – Identify issues before on-site installation
• Faster Deployment – Shorten start-up and ramp-up timelines
• Lower Costs – Minimize rework and unplanned downtime
• Improved System Performance – Optimize motion, logic, and cycle times
• Higher Confidence – Validate system behavior prior to production

Industries Served

• Automotive and Tier Suppliers
• Industrial Manufacturing
• Medical Device Manufacturing
• Aerospace
• General Manufacturing

Our Process

1. System Definition – Capture requirements, layouts, and automation logic
2. Digital Model Development – Build virtual representations of equipment and processes
3. Simulation & Testing – Validate motion, controls, and system interactions
4. Virtual Commissioning – Test automation logic under real-world scenarios
5. Deployment Support – Transition validated systems to on-site installation

Why DiFACTO

• Expertise in robotics, controls, and digital engineering
• Practical application of simulation for real-world automation
• Reduced risk through early validation
• End-to-end support from concept to commissioning

Validate Before You Build

DiFACTO’s digital simulation and virtual commissioning services help ensure automation systems work as intended—before they reach the factory floor.

Contact us to learn how virtual commissioning can de-risk your automation project.