Had enough of theory? As an engineer or production manager, the STIWA digital machine model helps you avoid errors during commissioning, save retrofit costs, and get control centers that are ready for immediate use. Discover practical solutions for error-free production from planning to series production.
Imagine you could avoid errors during commissioning almost entirely, get an instantly usable control center, skip time-consuming retrofits, and reduce downtime measurably. That’s exactly what STIWA Software enables through a digital machine model. No hype, no buzzwords – just tangible relief in everyday operations.
Many blog posts stay abstract, but not this one. Here, you'll see exactly what you gain as a planner, designer, or production manager. With tangible examples, real project insights, and clear benefits without theoretical fluff. So you can decide for yourself: is this worth it or not?
Real-world example:
During the kickoff with an automotive customer, it became clear: to ensure full traceability, four additional sensors were required. Because this was identified early, the hardware planning was adjusted and a costly retrofit (over €20,000) was avoided.
What happens:
Joint kickoff with all stakeholders
Structured data concept is created
Traceability, interfaces (ERP/MOM), and rework concepts are defined early
Your benefit:
Clarity & structure from the start
No surprises during commissioning
Lower retrofit costs
“In the past, we only realized what was missing during commissioning but today, we know it before the system is built.” – Project manager at a mechanical engineering company
Real-world example:
A system with 18 stations was digitally modeled, including all process parameters, special functions, and product variants. The result: 100% of PLC-relevant data was available before a single cable was laid.
What happens:
A virtual data machine model is built
An implementation guide for PLC integration is created
Recipe management & special functions are specified
Your benefit:
All requirements are included in the system
Fewer questions & feedback loops in PLC programming
1:1 process implementation from the model
Best practice:
A control center with OEE, downtime, and alarm analysis was generated automatically from the digital data model. Already during testing, issues with "Type B", the part handling and a special workpiece carrier were detected.
What happens:
Control center & analysis HMI's are created automatically
PLC function blocks for integration are delivered
No manual HMI programming required
Your benefit:
Time savings in PLC & HMI development
Real HMI can be used during testing
Early detection of bottlenecks
Concrete outcome:
In a medical tech project, automated data collection during commissioning revealed process fluctuations and a faulty feed mechanism that could have led to high scrap rates in serial production.
What happens:
Live process analysis
Early optimization
Acceptance with fact-based protocol
Your benefit:
Commissioning on a real data basis
Acceptance based on facts, not gut feeling
Less scrap from day one
Example:
A mechanical adjustment led to shorter cycle times, proven through before/after comparison in Analysis-CI. Decision: keep the change. ROI was achieved in record time.
What happens:
Real-time analysis & trend tracking
Before/after comparisons
Quality assurance via ERP, M2M & user management
Your benefit:
More efficient coordination with the machine builder
Faster ramp-up
Stable cycle times & quality
From the field:
Six months later, a new product was integrated without reprogramming the PLC. Only the configuration was adapted, and a new UI & analysis were automatically generated.
What happens:
Regular updates (2x per year)
Flexibility for product changes
Long-term support & development
Your benefit:
Minimal training effort for upgrades
Investment security
Continuous improvement with real data
If you're a practitioner looking for real results, this is for you. STIWA Software doesn’t just deliver pretty screenshots; we deliver fewer errors, less scrap, shorter commissioning phases, and higher efficiency. Tangible, measurable, and tested in real machine building.
Become the driver of your production: Discover how STIWA Software's digital twin optimizes your entire machine lifecycle, minimizes errors, and…
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