Improving quality control in automation projects using simulation systems

Abstract: Automation systems are becoming more and more integrated in today’s society. The complexities of these systems are increasing and with this, the demand for high quality during the developmental phases. This poses a challenge for companies developing systems. One solution emerging form this issue is the use of simulations and virtual commissioning.  In the thesis, the process of quality control and the effective use of simulations in automation system development projects are studied. The focus lies on the software part of the systems. The study was conducted as an interview study of personnel at an automation systems development company. After conducting the interviews, the information was analyzed. This was combined with general theory regarding quality control and testing methods in software development. The test methods of the quality control process were then combined with what was required by a simulator in order to preform them.  The results of the thesis is a detailed picture of the quality control process. Systems are tested twice with the same testing hierarchy, first during development and then during commissioning. The difference is that during development, the final physical hardware and process system are not conceded to the software. This impacts the software system functionality and limiting its testability. Using simulations during development can reduce the disparity between the systems before and after deployment, improving quality. Considerations regarding the extent of simulation need to be made in order for the value of the simulators’ error removing potential to be higher than the cost of developing the simulator.