Remote Commissioning: Unlocking Efficiency and Flexibility in Industrial Operations

Before a customer can bring your machine online, it must pass a rigorous commissioning process—every system, component, and setting is verified against the customer’s operational requirements. Today, remote commissioning makes this essential step faster, cheaper, and more reliable.

What Is Remote Commissioning?

Remote commissioning lets you install, configure, and validate industrial equipment from a distance. During pre‑commissioning you review PLC parameters, verify process integrity, and troubleshoot fault codes—all without stepping onto the plant floor.

Through a secure internet connection, the PLC program and HMI panel can be monitored and controlled from anywhere. In the following case studies, we illustrate how this capability translates into real-world benefits.

Making Your Machines Remotely Accessible

The first step is to embed connectivity into your machinery. By installing a VPN router on the PLC controller, robot, and HMI panels, you create a secure tunnel to the cloud. From there, authorized users can access the equipment over a protected VPN link.

DC Airco, a Dutch HVAC specialist, faced commissioning delays during the Covid‑19 lockdowns when on‑site visits were impossible. They adopted the IXON Cloud platform, installing an IXrouter in each unit to enable remote assistance throughout installation and acceptance testing.

Marc Schimmel, service engineer at DC Airco, explains: “The installation is simple for the customer, and we can conduct the commissioning together online. I get an immediate connection to their network, which is far faster than a phone call because I can see exactly what’s happening in real time.”

Read the full story of DC Airco here.

Augmented Reality for Complex Commissioning

When a machine’s commissioning depends on external systems or intricate assembly, a hybrid approach can be invaluable. Combine remote access with video or augmented reality (AR) using a Microsoft HoloLens.

For example, your team can ship parts to a customer along with an instructional video that demonstrates the assembly process. Alternatively, the HoloLens offers live 3D holographic overlays—such as manuals and component annotations—visible through transparent lenses. Meanwhile, the machine builder on the other side receives a live camera feed via a web portal.

One customer shipped a unit to Dubai with an IXrouter and HoloLens. The engineer in the Netherlands accessed the PLC and HMI via IXON Cloud, while the HoloLens displayed the on‑site view for the Dubai team. The engineer could label parts and issue real‑time instructions, effectively mirroring an on‑site presence.

Through the IXON Cloud platform, the Dutch engineer monitored the PLC, controlled the HMI, and used TIA Portal on his PC to annotate components over a secure VPN. The experience was indistinguishable from an in‑person visit.

Advantages of Remote Commissioning

Remote commissioning delivers measurable gains:

• Cost Reduction: Eliminates flight, lodging, and transportation expenses, lowering overall commissioning costs for the customer while preserving revenue for the builder.
• Productivity Boost: Engineers can focus on troubleshooting without on‑site distractions and can juggle multiple projects concurrently.
• Enhanced Collaboration: All stakeholders—engineers, customers, and service teams—access identical data securely and in real time from any location.
• Rapid Turnaround: Immediate remote access speeds up diagnostics and fixes, shortening commissioning timelines.

Ready to experience the benefits of remote commissioning with IXON Cloud?

Request our IXrouter trial kit here