<\/p>\n\n\n\n
The Vision<\/h3>\n\n\n\n
The infinite symbol illustrates a central vision: the various life cycle phases of a production system are interlinked, from the idea over planning to commissioning and optimization. Each phase is closely connected to the next one. The infinite symbol represents not only the infinite process, but also the adaptability and continuous improvement of modern production systems.<\/p>\n\n\n\n
The Lifecycle Phases<\/h3>\n\n\n\n
The life cycle of a production system comprises numerous phases that can span several years or even decades. The infinite symbol divides the life cycle of a production system into various interlinked process steps:<\/p>\n\n\n\n
- \n
- Planning:<\/mark><\/strong>
In this phase, the foundation for the future production system is established. Planners work to develop a vision and translate it into concrete plans.<\/li>\n<\/ul>\n\n\n\n<\/p>\n\n\n\n
- \n
- Engineering and Simulation:<\/mark><\/strong><\/strong>
The digital model is gaining traction. Design engineers develop the production system using modern software tools, while simulators test the system via simulations.<\/li>\n<\/ul>\n\n\n\n<\/p>\n\n\n\n
- \n
- Virtual Commissioning:<\/strong>
<\/mark>In this phase, the control logic of the production system is tested and optimized using a digital twin before actual commissioning. Virtual commissioning reduces risks and ensures a smooth transition to the real world.<\/li>\n<\/ul>\n\n\n\n<\/p>\n\n\n\n
- \n
- Commissioning:<\/mark><\/strong>
The physical plant is built, tested, and put into operation.<\/li>\n<\/ul>\n\n\n\n<\/p>\n\n\n\n
- \n
- Ramp-up:<\/mark><\/strong>
The ramp-up phase of a production system describes the period after commissioning during which production is gradually ramped up from initial test runs to the planned series output. During this phase, processes are stabilized, parameters are optimized, and quality and performance targets are achieved. The goal is to achieve reliable, reproduceable, and economical series operation of the system.<\/li>\n<\/ul>\n\n\n\n<\/p>\n\n\n\n
- \n
- Operations and Production:<\/mark><\/strong>
The production system is now in series operation and is monitored using digital shadows. But even here, the life cycle does not end\u2014rather, continuous development begins.<\/li>\n<\/ul>\n\n\n\n<\/p>\n\n\n\n
- \n
- Training and education:<\/strong>
<\/mark>Even as technology advances, humans remain a crucial factor in the life cycle of a production system. Programming, operating, and maintaining modern systems requires specialized knowledge that must be learned through comprehensive training. Operators, maintenance engineers, and control logic programmers are trained using the digital model to ensure smooth operations. Realistic scenarios can be simulated to train responses to malfunctions or emergencies. This reduces the risk of errors and increases safety.<\/li>\n<\/ul>\n\n\n\n<\/p>\n\n\n\n
- \n
- Analysis and Optimization:<\/strong><\/strong>
<\/mark>During ongoing operations, the production system is continuously analyzed and optimized. Thanks to digital models, bottlenecks and weaknesses can be identified and addressed based on data. Optimization measures can first be tested on the virtual model without disrupting ongoing operations. This prior validation also ensures a smooth restart of the system.<\/li>\n<\/ul>\n\n\n\n<\/p>\n\n\n\n
![\"\"](\"https:\/\/www.eks-intec.com\/wp-content\/uploads\/2026\/03\/Production-Lifecycle-EKS-1024x579.avif\")
<\/figure>\n\n\n\nDigital Model \u2013 The key to efficiency<\/h3>\n\n\n\n
A key aspect of modern production systems is the use of digital models, which are created during the planning phase or can be used directly from virtual commissioning, e.g., for cycle time optimization or collision checks. Various use cases can be implemented here, see also [1]:<\/p>\n\n\n\n
Online<\/em><\/strong><\/h4>\n\n\n\n
<\/p>\n\n\n\n
- \n
- Use Case 1: Virtual Sensing<\/strong>
<\/strong>Virtual Sensing enables real measurement variables to be determined from a virtual model by interlinking simulations running in parallel to the operation of the real systems. This allows a distinction to be made between control-relevant and additional information, enabling live collision avoidance.
Suitable tools from RF::SUITE: ViPer, FMU environment, OPC UA-Connect, Connect Tools, assistance tools
<\/li>\n<\/ul>\n\n\n\n<\/p>\n\n\n\n
- \n
- Use Case 2: Monitoring<\/strong>
<\/strong>Production processes can be monitored and controlled more effectively using simulations that run parallel to operations. Visualizations such as diagrams or 3D models enable intuitive and precise process monitoring, which increases efficiency and safety.
Suitable tools from RF::SUITE: YAMS, ViPer, Scout, Connect Tools, Recorder, VR, assistance tools
<\/li>\n<\/ul>\n\n\n\n<\/p>\n\n\n\n
- \n
- Use Case 3: Anomaly detection<\/strong><\/strong>
<\/strong>Anomaly detection analyzes historical data that has been recorded to determine \u201cnormal\u201d behavior and compare it with current process data (data analysis). This enables a target\/actual comparison (digital twin – digital shadow) with the real plant or the collection of data from various sources.
Suitable tools from RF: SUITE: YAMS, Viper, SCOUT, Recorder, Connect Tools, assistance tools
<\/li>\n<\/ul>\n\n\n\n<\/p>\n\n\n\n
- \n
- Use Case 4: Prediction<\/strong>
<\/strong>Prediction provides insights into the future development of the system by comparing current and past behavior of the production system. With the virtual commissioning model, collision detection, energy and material consumption can be optimized, and predictive maintenance can be realized.
Suitable tools from RF::SUITE: YAMS, ViPer, Scout, Connect-Tools, Recorder, Cereb, external database, assistance tools
<\/li>\n<\/ul>\n\n\n\n<\/p>\n\n\n\n
Offline<\/em><\/strong><\/h4>\n\n\n\n
<\/p>\n\n\n\n
- \n
- Use Case 5: Scenario analysis<\/strong>
<\/strong>Scenario analysis (during virtual commssioning or in the subsequent operating phase) supports decision-making in complex systems by simulating various scenarios. It helps to evaluate the effects of changes, such as new control programs or adjustments to the production system.
Suitable tools from RF::SUITE: YAMS, Viper, SCOUT, Recorder, Connect Tools, FSBox, assistance tools<\/li>\n<\/ul>\n\n\n\n<\/p>\n\n\n\n
- \n
- Use Case 6: Diagnosis<\/strong>
<\/strong>Diagnosis aims to identify sources of error and undesirable behavior quickly and transparently. Simulations allow errors to be reproduced and analyzed without affecting the real system.
Suitable tools from RF::SUITE: Rekorder, Scout, Connect Tools, databases, assistance tools, whole RF::Suite<\/li>\n<\/ul>\n\n\n\n<\/p>\n\n\n\n
- \n
- Use Case 7: Training of Machine Learning Models<\/strong>
<\/strong>Simulations provide synthetic data for the use in artificial intelligence processes and models. Their flexibility helps to avoid problems such as bias and to train complex scenarios reliably.
Suitable tools from RF::SUITE: Scout, Recorder, evtl. Connect Tools, databases, assistance tools<\/li>\n<\/ul>\n\n\n\n<\/p>\n\n\n\n
- \n
- Use Case 8: Training<\/strong>
<\/strong>The virtual commissioning model enables realistic training for the operation and maintenance phase of production systems. Critical situations can be simulated without affecting the real system or production times. Virtual systems can also be used to learn control programming, even in conjunction with predefined libraries.
Relevant tools from the RF::SUITE: RF::EdDi<\/li>\n<\/ul>\n\n\n\n<\/p>\n\n\n\n
- Use Case 8: Training<\/strong>
- Use Case 7: Training of Machine Learning Models<\/strong>
- Use Case 6: Diagnosis<\/strong>
- Use Case 5: Scenario analysis<\/strong>
- Use Case 4: Prediction<\/strong>
- Use Case 3: Anomaly detection<\/strong><\/strong>
- Use Case 2: Monitoring<\/strong>
- Use Case 1: Virtual Sensing<\/strong>
- Analysis and Optimization:<\/strong><\/strong>
- Training and education:<\/strong>
- Operations and Production:<\/mark><\/strong>
- Ramp-up:<\/mark><\/strong>
- Commissioning:<\/mark><\/strong>
- Virtual Commissioning:<\/strong>
- Engineering and Simulation:<\/mark><\/strong><\/strong>