What’s in it for me as a practitioner?
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.
Practice, not theory: Tackling real-world challenges
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?
1. Engineering – Plan digitally instead of retrofitting
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:
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Joint kickoff with all stakeholders
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Structured data concept is created
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Traceability, interfaces (ERP/MOM), and rework concepts are defined early
Your benefit:
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Clarity & structure from the start
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No surprises during commissioning
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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
2. Project Planning – The digital data twin is born
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:
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A virtual data machine model is built
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An implementation guide for PLC integration is created
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Recipe management & special functions are specified
Your benefit:
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All requirements are included in the system
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Fewer questions & feedback loops in PLC programming
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1:1 process implementation from the model
3. Design & Assembly – Control center & analysis out-of-the-box
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:
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Control center & analysis HMI's are created automatically
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PLC function blocks for integration are delivered
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No manual HMI programming required
Your benefit:
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Time savings in PLC & HMI development
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Real HMI can be used during testing
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Early detection of bottlenecks
4. Commissioning & Pre-Acceptance – Catch issues before they get expensive
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:
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Live process analysis
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Early optimization
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Acceptance with fact-based protocol
Your benefit:
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Commissioning on a real data basis
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Acceptance based on facts, not gut feeling
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Less scrap from day one
5. Ramp-Up – Start-up based on facts, not gut feeling
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:
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Real-time analysis & trend tracking
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Before/after comparisons
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Quality assurance via ERP, M2M & user management
Your benefit:
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More efficient coordination with the machine builder
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Faster ramp-up
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Stable cycle times & quality
6. Serial Production – The system evolves with you
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:
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Regular updates (2x per year)
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Flexibility for product changes
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Long-term support & development
Your benefit:
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Minimal training effort for upgrades
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Investment security
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Continuous improvement with real data
Conclusion
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.
Would you like to learn more? We are here for you!