Worldwide Commissioning: A Field Report from 30+ Projects

1.Introduction

6 AM at Frankfurt Airport. Boarding call for flight to Detroit. In luggage: laptop, multimeter – and a small tool kit.

Worldwide commissioning is more than just "loading PLC code onto the machine". It's project management under time pressure, troubleshooting with limited resources, and intercultural communication.

In this article, I share my experiences from over 30 international commissioning projects – from preparation through workshop testing to final on-site acceptance at the end customer. With lessons learned, checklists, and concrete practical examples.

2.Phase 1: Preparation (6-8 Weeks Before Departure)

2.1.The Underestimated Phase

Many commissioning projects fail not on-site but in preparation. 60% of all commissioning problems can be avoided through proper workshop testing.

2.2.Workshop Testing - The Foundation

Definition: The customer accepts the machine BEFORE shipping at the machine builder's facility.

My Checklist (3-5 Days):

1. Day 1: Mechanics & Electrics

   • All motors rotate in correct direction?
   • Safety circuits functional (E-STOP, light curtains, safety PLC)
   • Pneumatics/Hydraulics: Pressures OK, no leaks

2. Day 2: Software Functions

   • All operating modes (Auto, Manual, Setup)
   • Recipe management, data logging
   • Alarm handling: Provoke at least 50 error scenarios!

3. Day 3: Performance Tests

   • Cycle times under load
   • 24-hour endurance test (yes, really 24h!)
   • Statistical analysis (Cpk values for critical parameters)

4. Day 4: HMI & Operation

   • Customer team training
   • User Acceptance Testing (UAT)
   • Feedback round: What's still missing?

5. Day 5: Documentation Handover

   • Circuit diagrams (updated!)
   • PLC program (Source + Compiled)
   • Operating manual in customer language
   • Spare parts list with supplier contacts

2.3.Document Management

Checklist for International Projects:

• Passport (Validity > 6 months)
• Visa (B1 for USA – lead time 4-8 weeks!)
• CE Declaration of Conformity (English + local language)
• Technical Documentation (Circuit diagrams, PLC program, operating manual)
• International Health Insurance (Travel insurance is NOT enough!)
• Invitation Letter from customer (for visa application)
• Emergency Contacts (Embassy, client contact)

Pro Tip: Store all documents as PDFs in the cloud (Google Drive, Dropbox). Physical copies separate from main luggage.

3.Phase 2: On-Site at Customer

3.1.Day 1: Site Assessment & Acclimatization

Don't rush into the machine immediately!

First 2-3 hours:

1. Facility tour with local team
2. Check IT infrastructure (Internet quality for VPN!)
3. Safety briefing (Emergency exits, first aid, local rules)
4. Move tools to secure room

Cultural Pitfalls (Experiences):

• USA (Michigan): Very direct, quick decisions. "Let's fix it NOW" – overtime normal.
• Japan: Respect hierarchy! Make decisions only with manager. Very reserved and shy. "Yes" often means "I understood", not "I agree".
• Africa (Tanzania/Malawi): Time management more flexible. Be patient! Don't forget sunscreen – sunburn comes faster than you think.

3.2.Day 2-7: Software Commissioning

Typical Schedule:

06:00 - 08:00 Preparation (Team meeting, discuss daily goals)

08:00 - 12:00 Main work (Check wiring, load software, first tests)

12:00 - 13:00 Lunch (IMPORTANT: Eat with local team → Build trust!)

13:00 - 18:00 Troubleshooting, optimization

18:00 - 20:00 Documentation, save logs

20:00+ Optional: Remote meetings with Germany (time difference!)

3.3.Troubleshooting Under Pressure

Case 1: Motor Doesn't Rotate (Japan, 2019)

Problem: Main drive doesn't start. Time pressure: Production starts in 48h.

Systematic Approach:

1. Hardware check: 24V OK, motor protection OK, contactor does NOT switch
2. Signal tracing: PLC output %Q0.0 = TRUE (Software OK)
3. Wiring: Continuity test → Cable break in cable duct!
4. Root Cause: Mechanic damaged cable during installation

Lessons Learned: When "motor doesn't run", ALWAYS check hardware first, not software!

Case 2: HMI Shows Wrong Values (Poland, 2022)

Problem: Temperature display shows -273°C (physically impossible).

Root Cause: Scaling in HMI incorrectly configured (°F instead of °C).

Lessons Learned: Unit tests also for HMI visualizations! (Read mock data, check displays)

3.4.Using Remote Support Effectively

Setup (Clarify BEFOREHAND!):

• VPN access to PLC (Coordinate firewall rules with IT beforehand!)
• TeamViewer/AnyDesk installed on local PC
• WhatsApp/Signal group with engineering team in Germany

Best Practice:

• Send screenshots/videos of problems (not just text!)
• Automatically send log files to Germany via FTP
• Daily 30-min status call with home office (fixed time!)

3.5.Day 8-10: Performance Optimization & Training

Not just "runs" – but "runs optimally"!

Optimization Examples:

• Cycle time reduced from 45s to 38s (16% productivity increase!)
• Scrap rate from 3.2% to 0.8% through sensor fine-tuning
• Energy consumption -12% through optimized sequential control

Training Local Team:

DO:

• Hands-on training (not just PowerPoint!)
• Create checklists for common faults
• Enable "First Level Support" (90% of problems are simple)

DON'T:

• Explain everything at once (Overload!)
• Train only in English (Organize interpreter!)
• Without written documentation (Forgetting is human)

3.6.Day 11-14: Final Acceptance

Customer tests EVERYTHING again:

• Run production dummies (if possible: real products!)
• Collect quality data (Cpk values, measurement reports)
• 24h endurance run under production conditions

Documentation:

• Have acceptance protocol signed (legally binding!)
• Photos of final system (Evidence for later complaints)
• Handover of ALL access data (Passwords, VPN access, cloud accounts)

4.Phase 3: After Acceptance – The Often Forgotten Part

4.1.Follow-Up Support (30 Days)

Best Practice: 30-day support guarantee after acceptance.

Typical Support Calls:

• Week 1: 3-5 calls (normal startup issues)
• Week 2: 1-2 calls
• Week 3+: < 1 call per week

If more calls: Plan return flight or commission local partner.

4.2.Lessons Learned & Documentation

Post-Project Review (Internal):

1. What went well?
2. What went wrong?
3. Which problems repeat? (Analyze root cause!)
4. Can workshop testing be improved?

Update Documentation:

• Circuit diagrams (always!)
• PLC program (archive final version)
• Operating manual (Errata list if errors found)

5.The 10 Biggest Mistakes in International Commissioning

1. No proper workshop testing → 60% of problems avoidable
2. Underestimating jet lag → Concentration suffers massively (especially Japan with 8h time difference)
3. Forgetting emergency medication → Food intolerance is a real problem (especially Africa)
4. Ignoring cultural differences → Communication breakdown
5. Forgetting sunscreen → Quick sunburn in Africa
6. Underestimating on-site IT infrastructure → No VPN, no internet
7. Not training local team → 1000 support calls after departure
8. Skipping 24h endurance test → Errors only visible after weeks
9. No buffer days → One problem = entire schedule collapses
10. Documentation in German → Customer can't understand anything

6.My Personal Packing List

6.1.Carry-On (Never Check!)

• Laptop + charger
• Power bank (20,000 mAh)
• Noise-canceling headphones (Lifesaver on long-haul flights!)
• Travel adapter (Universal World to World adapter)
• USB sticks with ALL software versions (TIA Portal, HMI projects)
• First aid kit (Painkillers, anti-diarrhea tablets!)

6.2.Checked Luggage (Essential!)

• Tool case (Screwdrivers, pliers, wire cutters) – INDISPENSABLE!
• Multimeter (Fluke 87V)
• LAN cables (Cat6, 10m + 20m)
• WLAN router (for local network if poor on-site)
• Profinet cables and various adapters
• Clothing (Business + Casual – AC can be very cold!)

7.Conclusion: The Best Experiences of My Life

Worldwide commissioning is exhausting, stressful – but incredibly enriching.

What I've Learned:

• Technical knowledge alone isn't enough – soft skills are 50% of success
• Cultural differences aren't obstacles, but enrichment
• A good workshop test is worth gold
• Local partners are more important than the best equipment

Personal Highlights:

• Japan: Working with the reserved but incredibly precise team. The jet lag was brutal (8h time difference), but the experience priceless. Eating sushi the way Japanese people celebrate it – completely different style than ours! In free time: explored Tokyo, the beautiful temples and gardens in Kyoto, and Osaka with its cool skater/hip-hop culture and nightlife.

• Africa: A few days vacation on Zanzibar after the project in Tanzania/Malawi – unforgettable!

• USA: After the Michigan project: Miami, Key West, New York, Chicago – America at its best.

• "Thank you, you saved our production!" – the best compliment you can receive.

8.Further Resources

• Visa Information: German Foreign Office
• International Health Insurance: BDAE Group
• Cultural Preparation: Hofstede Insights

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About the Author: David Prybisch has been involved in worldwide commissioning for over 10 years. He has commissioned machines and production lines in over 30 projects across 4 continents.