The on-site commissioning is a vital milestone for the project lifecycle of a manufacturing system. This process also plays a crucial role in the future financial accomplishment of the manufacturing system. From the point of view of control systems associated with the manufacturing system, the most common problems encountered during the commissioning process are related to the software. However, early detection of these software-related problems is possible by enabling virtual commissioning technology.

The control system of the manufacturing system investigated within the scope of this thesis is developed by Midroc Automation AB. In the thesis, simulation and simulation model creation approaches, further benefits of the simulation model along the life cycle of the manufacturing system and PLC code validation possibilities with virtual commissioning are analysed by considering qualitative and quantitative advantages of virtual commissioning. The work is performed using SIMIT for the development of the virtual plant model, PLC-SIM Advanced for simulation of PLC controller and TIA Portal for validation of the control system.

The experiment attempts to develop a virtual commissioning environment by applying the model-based virtual commissioning approach. Furthermore, software in the loop configuration is used to simulate the real PLC controller. This attempts demonstrates whether it is possible to validate the control system. The results are that the validation of the control system is possible considering the objectives, technical and commercial limits of the automation project. Ultimately, efficient use of time-saving tools in the preparation of the necessary environment for virtual commissioning is provided.