Automotive Industry
Simulation & Virtual Commissioning
It all begins with accurate simulation.
Our team create Robot OLPs (Offline Programs) in a virtual environment prior to stepping foot on site. This ensures the programs are error-free and ready for a smooth transition into production, minimising downtime and optimising cycle times.
Once the OLPs are created, we use Siemens Process Simulate to run the robot paths alongside the PLC logic, allowing us to debug and refine both in a realistic virtual model of your production line. By testing interlocks, I/O, safety signals and sequence control in this digital twin, we identify and resolve issues long before commissioning, so on-site launch is faster, safer and far more predictable.
On Site PLC Commissioning
Once the project moves to its site implementation phase, our PLC software engineers perform systematic verification of all input and output points to ensure wiring and device signals match the design specifications. Comprehensive I/O checks include testing sensors, switches, actuators, and communication interfaces to confirm correct installation and signal integrity.
Safety systems such as emergency stops and protective interlocks are rigorously tested to validate fail-safe operation. We also run automatic test sequences aligned with the production process to debug the control logic and verify system responses under real operating conditions and failure modes.This structured approach minimizes risks and ensures the PLC system operates reliably, whether it is tied to new equipment or integrated into existing production lines.
On Site Robot Programming
Our team specialises in on‑site robot programming and commissioning for complex automotive production environments. Working from the initial offline programs developed in Process Simulate, we bring production lines to life by refining, validating, and optimizing robot paths directly on the shop floor.
With extensive experience in paint, body‑in‑white, and assembly applications, we ensure smooth integration between simulation and real‑world operation. Our robot programmers fine‑tune motion sequences, tool interactions, and process parameters to achieve cycle time targets, quality standards, and safety requirements.
From initial power‑on through to full production readiness, we work alongside OEM and Tier‑1 teams to deliver efficient, reliable, and fully validated robotic systems ready for volume manufacturing.
