We offer high-quality, punctually, customized, and trend-setting solutions for the entire production life cycle. This is represented by the “infinity symbol” and stands for continuous development, optimization, and transformation, which are crucial in the field of industrial manufacturing.
In this blog post, we discuss the different phases of the infinite lifecycle. We focus on virtual commissioning, training, and analysis and optimization, and show how digitalization and innovative technologies support this process.
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.
The Lifecycle Phases
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:
- Planning:
In this phase, the foundation for the future production system is established. Planners work to develop a vision and translate it into concrete plans.
- Engineering and Simulation:
The digital model is gaining traction. Design engineers develop the production system using modern software tools, while simulators test the system via simulations.
- Virtual Commissioning:
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.
- Commissioning:
The physical plant is built, tested, and put into operation.
- Ramp-up:
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.
- Operations and Production:
The production system is now in series operation and is monitored using digital shadows. But even here, the life cycle does not end—rather, continuous development begins.
- Training and education:
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.
- Analysis and Optimization:
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.
Digital Model – The key to efficiency
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]:
Online
- Use Case 1: Virtual Sensing
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
- Use Case 2: Monitoring
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
- Use Case 3: Anomaly detection
Anomaly detection analyzes historical data that has been recorded to determine “normal” 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
- Use Case 4: Prediction
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
Offline
- Use Case 6: Diagnosis
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
- Use Case 7: Training of Machine Learning Models
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
- Use Case 9: Support in Design
Modern software tools can assist in design either through rule-based approaches or AI support, taking over certain steps of the design process. This can include partially automated design of clamping fixtures, robot positioning, and more.
Relevant tools from the RF::SUITE: RF::GUARD
The infinity symbol – more than a symbol
The infinity symbol is more than just a symbol—it represents a new era in industrial manufacturing, in which continuous change is actively embraced as an opportunity. Virtual commissioning, continuous analysis and optimization, and training based on digital models are revolutionizing the life cycle of production systems. Planning and commissioning are becoming more efficient. The production system becomes more reliable and resilient to failures and changes. Realistic training opportunities empower the persons involved. With the help of modern technologies and digital models, production systems can be continuously adapted to tomorrow’s requirements.
The future of industrial manufacturing is being actively shaped by innovative software solutions and advanced engineering!
Further information on the RF::SUITE tools: https://www.eks-intec.com/platform/products
Source:
[1] Malte Ramonat, Darius Deubert, Lars Klingel, Tina Mersch, Roland Rosen, Jens Jäkel, Ronald Schmidt-Vollus, Omar Ismail, Miriam Schleipen: Weiterverwendung von Simulationsmodellen aus der VIBN: Anwendungsfälle, Anforderungen und Handlungsempfehlungen für die Betriebsphase. Automation 2025 : human-centric automation ; 26. Leitkongress der Mess- und Automatisierungstechnik : 1. und 2. Juli 2025, Baden-Baden / VDI/VDE-Gesellschaft Mess- und Automatisierungstechnik, VDI-Wissensforum, S. 495-533, 2025.
