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Virtual Commissioning

Half the Machine! Twice the work!

Simulate, Validate, and Deploy Smarter

In today’s fast-moving industrial environment, automation projects demand precision. At MN Engineering Solutions, we help manufacturers digitally simulate their machines, logic controls, and process flows before anything goes live on the factory floor. Using digital twin technology and virtual twins, we enable real-time testing of PLC and SCADA configurations—minimizing integration errors, reducing downtime, and ensuring seamless implementation. Our virtual commissioning approach is a vital part of digital transformation, giving you the confidence to optimize performance without disrupting existing operations.

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Why do you need Virtual Commissioning?

Test automation logic and PLC code before actual deployment
Validate SCADA/HMI workflows and sensor integrations virtually
Reduce downtime during installation and commissioning
Accelerate project timelines with simulation-driven development
Enhance project quality with full digital traceability
One of our

project on Virtual Commissioning

MN Engineering Solutions helped a global specialty equipment manufacturer reduce lead time and development costs by implementing a digital twin-based virtual commissioning solution. Facing a tight project deadline and limited in-house expertise, the client struggled with early detection of software and mechanical issues. MNES developed a synchronized simulation environment using NX-MCD and PLCSIM, enabling early validation and 95% accurate testing before physical commissioning. This streamlined the process, cut lead time by two months, and lowered costs by 20%.

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Why wait to debug on-site when you can simulate in advance?

MNES delivers virtual commissioning using digital twins that mimic plant conditions—enabling real-time logic testing, faster ramp-up, and smoother automation rollouts. Whether you’re commissioning a packaging line or an entire factory, our approach reduces time, cost, and complexity.

Explore how this aligns with our Digital Twin Technology and accelerates Digital Transformation across manufacturing.

Let's Discuss

Our CapabilitiesSupport from MNES for Virtual Commissioning Services:

  • PLC Logic Simulation – Test ladder logic, function blocks, and SCL in a virtual setup
  • SCADA/HMI Integration – Validate UI screens, tag flows, alarms, and visualizations
  • Digital Twin Modeling – Create a virtual twin of your plant floor with real-time physics and I/O mapping
  • Robot and Mechatronic Simulation – Simulate robotic arms, sensors, and actuators with motion logic
  • Hardware-in-the-loop (HIL) – Connect real PLCs with simulated environments for dynamic testing
  • Virtual FAT (Factory Acceptance Test) – Conduct remote acceptance tests using virtual environments
  • Integration with MES & ERP – Simulate complete system behavior before full production rollout

Our Custom SolutionsPlatforms & Tools

  • Siemens NX Mechatronics Concept Designer
  • TIA Portal + S7 PLCSIM Advanced
  • WinCC for SCADA/HMI simulations
  • Factory I/O, ISG Virtuos, SIMIT
  • OPC UA, Modbus, MQTT, and custom APIs
  • Python & MATLAB for control logic scripting

FAQs

1. What is a Virtual Twin?

A Virtual Twin is a real-time digital replica of a physical machine or process. It simulates and monitors actual operations, allowing engineers to test and optimize performance virtually before implementation.

2. What is Virtual Commissioning?

Virtual Commissioning is the process of testing and validating control systems (PLC logic, HMI, etc.) using a Virtual Twin before deploying them on physical machines. It helps detect errors early and reduces startup time.

3. What are the benefits of Virtual Commissioning?
  • Early detection of software or integration issues
  • Reduced commissioning time and costs
  • Improved system reliability and performance
  • Safer testing without physical risks
4. Which automation systems can be simulated before commissioning?

You can simulate programmable logic controllers (PLCs), robotic arms, sensor-actuator systems, and SCADA interfaces across various plant operations.

5. What tools are used for Virtual Commissioning?

Common tools include Siemens TIA Portal, PLCSIM, NX MCD, Automation Studio, and other simulation platforms that connect mechanical models with control systems.

6. Which industries benefit from virtual commissioning and digital transformation?

Automotive, electronics, packaging, and food processing industries gain most when upgrading automation as part of digital transformation.

7. Is virtual commissioning useful for remote engineering teams?

Definitely. It allows remote testing, collaboration, and factory acceptance tests (FAT) without needing physical presence—ideal for distributed automation teams.

Let’s Start Your Virtual Commissioning Journey

Commissioning shouldn’t be a bottleneck. Let MN Engineering Solutions help you simulate first and implement with confidence—backed by years of experience in industrial automation and digital transformation.

Lets Start

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Naresh Arunagiri

Naresh Arunagiri has several years of extensive experience in engineering services concentrating in Research and Development (R&D), New Product Development (NPD), lean manufacturing, work holding design, process & product optimization, production automation in the Truck & Trailer, Life science, and industrial machinery.

Naresh has extensively spent the last decade working in the truck and trailer industry in multiple companies in designing their walk-in-vans and trailer bodies with the focus on supporting them in different areas like,

• Body design (Body in white)
• Validating design based on FMVSS and DOT standards
• Light body EV vehicle designs
• Automotive electronics

He was instrumental in bringing out the first-in-class last-mile delivery electric vehicle and the fully electric campus shuttle bus to the market.

In the area of automation, Naresh was part of the team that designed and implemented the “Factory of the future” for one of the largest mattress manufacturing companies in the globe. This entailed designing a single flow layout aided by world-class technology of AGVs, Industrial Robots, and Cobots. His exceptional exposure to Technical sales and Application engineering in various industries, has been a great asset to MN Engineering Solutions.

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Madhan Kumar Paramahamsan

Madhan Kumar Paramahamsan has worked for 23 years as an engineering product lead with several well-known companies like Morgan Olson, Leser Gmbh., Pratt & Whitney, Hayssen Sandiacre, Thomas & Betts Inc, Cummins Inc, Babcock & Wilcox & Keld Ellentoft in multiple geographies, and diverse projects.

Performed across multiple challenging roles engineering domains in advanced design and validation, technical advice & consulting to teams in industries like Automobile, Aerospace, Packaging Industry, Defence, Infrastructure & Utilities (I&U), etc. Madhan has solid knowledge and years of experience with the I&U industry and also contributed significantly in the area of research & development.

Madhan’s keen interest in design and engineering paved way for certifications of all the major CAD/Simulation tools. The expertise in the years of design, fabrication, and engineering experience has been the key in leading Madhan to make MN Engineering Solutions one of the front-runners in the engineering services and solutions with a team of par excellence and with the largest supply chain management in the industry.

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Senthil Kumar Deivasigamany

Accomplished serial entrepreneur with a proven track record of building and growing businesses from scratch. Particularly adept at visioning and strategizing and most importantly, successfully executing on the vision. Experienced in multiple domains, including sales & marketing, HR, and operations with key skills in Organization Development and Sales Management.

Over the last three decades, he has had myriad experiences that reinforced the foundation to build businesses. The tenure as a Sales Engineer in Tube Investments and Product Manager in Sterling Holidays gave a strong footing in sales and marketing, spanning 10 years. During that time, he propagated the importance of strategy, discipline and process orientation in enriching the sales pipeline and improving conversion. A short stint at ABC Consultants enabled him to understand how to attract and retain the best talent available in the market across various domains.

In the last 20 years with Barry-Wehmiller, a consulting company offering solutions to the manufacturing & technology industries, he orchestrated the growth from 6 associates to many hundreds in roles including Project Manager, Operations Manager, Business Development, and Business Unit Head with complete P&L responsibility. During this period, he was responsible for starting and growing the technology practice. Since 2010, he has been solely responsible for global sales of Engineering Services for Barry-Wehmiller, growing the business from $4 million to over $23 million in a span of 4 years.

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Rohit Jani

Rohit Jani is a mechanical engineer with over 23 years of experience in the marketing industry. Rohit is the lead sales and business advisory member with MN Engineering Solutions. His unrelenting experience over the years in business development, sales, marketing, and operations, set-up businesses in a new market, and building sustainable partnerships. Also, Rohit’s expertise extends to QC and ISO compliance for industries, B2B Marketing, price negotiations across contracts, and project executions.

Rohit’s excellence in diverse business strategies and in-depth experiences for sales for IT and Engineering Services. He is key to interacting and bringing business clients to MN Engineering Solutions. Rohit’s professional career includes companies like Vetus, Barry Wehmiller, Barmag India, Sungrace Engineering, and NIR Cadtech.

Rohit has strong customer relationship building and networking capabilities, sourcing and vendor management, cross-selling of products across different markets. He is equipped with sound knowledge of IT tools, ERP and experienced in using modern marketing tools. Rohit works experience spans globally across the USA, China, Western Europe, Maldives, and Srilanka.

In Rohit’s career, he was awarded on many occasions as the ‘Best Sales Person of the Year’ and twice as the ‘Best Project Manager’ with Barry Wehmiller. Rohit is also a certified PDM Works Enterprise Implementation Professional and Solidworks professional.

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Krishnakumar Krishnan

Results-oriented professional with 30 + years of experience, proven knowledge of business consulting, business development, partnership development, client expectation management, Training and delivery management.

He managed global sales and marketing to position enterprise applications and services to mid-market manufacturing companies both in the US, India and Middle East markets. Likes to engage in roles that are around mentoring sales teams, develop a go-to-market strategy, building new partnerships, sales operation, training, and mentoring.

His expertise comes from building strategic partnerships & alliances, key account management, and customer relationship management.

Passionate about training, mentoring talent and developing empowered teams to deliver world-class service in addition to training teams in effective communication methodologies.Travelled extensively, able to appreciate different cultures, wide CXO network

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