More efficiency and quality in commissioning

Groundbreaking test strategy for PLC programs

The Challenge

Process engineering machines, which IFA Technology develops individually for its customers, can already be simulated and tested in parts before commissioning, but still had to be extensively tested on site at the customer’s premises. This process is time-consuming and costly, as it is largely manual and relies heavily on the expertise of individual, experienced specialists. The shortage of skilled workers in Germany further exacerbates this situation. At the same time, demands for shorter development cycles, reduced commissioning times and consistently high software quality are increasing. In view of this, IFA decided to digitalize the testing and commissioning process in order to sustainably improve efficiency and quality.

IFA Technology

Since 1980, IFA Technology has specialized in the construction of systems for process engineering. The company develops and distributes customized solutions for weighing, mixing, conveying and dosing solid and liquid materials worldwide. With its high standards of quality and precision, IFA relies on individual adaptations to meet the specific requirements and wishes of its customers.

How we helped

To optimize the testing process for PLC programs (programmable logic controllers), we developed, with the support of the PLC software engineers from IFA Technology, a groundbreaking test strategy. This approach combines guidelines from the ISO 29119 standard for software and systems engineering and established software development concepts, such as automated testing, version control and CI/CD (Continuous Integration and Continuous Deployment), into PLC programming – an area in which such approaches have rarely been applied to date. This allows us to close a crucial gap and increase efficiency, quality and sustainability in automation.

By enabling IT/OT convergence, the integration of IT systems with machine controls, and virtual commissioning, in which programs can be tested in a realistic simulation, we reduce on-site testing times, minimize dependencies on specialized knowledge and relieve the burden on skilled workers.

  • Testing and quality assurance: Automated tests identify errors that significantly improve stability and quality even before programs are implemented in machines.
  • Version control: Changes are documented, facilitating collaboration within the team and avoiding regressions.
  • CI/CD: Changes can be integrated automatically and seamlessly into existing programs – without interrupting operations.

Technologies

C#/.NET Git Jenkins Siemens Totally Integrated Automation Portal Siemens Test Suite Advanced Siemens SIMIT Simulationsplattform Siemens SIMATIC S7-PLCSIM Advanced Siemens Version Control Interface Siemens TIA Portal Openness Interfaceh PLC(SPS) Testing

Project start                    Project volume

2023                                              3 XITASOnians

Other projects

Are you interested in a project, a service or do you have any other questions?

Michael Knoblich

Tel. +49 821 885 882-201
michael.knoblich@xitaso.com