How modern machine control really works

Proven methods from successful customer projects show how companies can reduce complexity, accelerate
commissioning and scale engineering sustainably.

Modern control that really works

Proven methods from successful customer projects show how companies can reduce complexity, accelerate
commissioning and scale engineering sustainably.

It works with Selmo

Find out how leading companies from the automotive, food and mechanical engineering sectors
have transformed their control processes with Selmo.
Best_Practice_mahle_logo_01 Best_Practice_thyssenkrupp_logo_01 Best_Practice_velox_logo_01 Best_Practice_digifai_logo_01 Best_Practice_igm_logo_01 Best_Practice_azo_logo_01 Best_Practice_magna_cosma_logo_01 Best_Practice_selmo_standard_logo_01 Best_Practice_exaron_logo_01

What successful projects have in common

Best_Practice_4points_01
Many industrial companies are struggling with the same challenges:
  • increasing complexity
  • long commissioning times,
  • hidden software logic
  • high dependence on individual experts.

Successful projects are created where behavior is visible, processes are structured and responsibility is clearly defined. This is exactly what our customer projects show in practice.

What makes successful projects measurable

Successful customer projects show how structured machine logic leads to faster
start-ups, greater transparency and sustainable performance.
Velox Werk GmbH Best_Practice_velox_logo_01
Stability in a few days.
5 days
Set to full process logic productive.
CONSTRUCTION MATERIALS - RETROFIT

Project - Retrofit of an automatic panel cutting system

Project type - Retrofit - Existing system

Approach - Process recorded via video + e-plan

Process model - 20 sequences - 254 steps - 330 zones

VIBN - Completed before real IBN

IBN duration - TwinCAT 3

IBN duration - 5 days full process logic

Result - WhiteBox monitoring detected hidden sensor errors.

igm robot systems Best_Practice_igm_logo_01
Competence made scalable.
1 engineer
Complete system modeled without previous PLC experience.
ROBOTICS - NEW INSTALLATION

Project - Robot welding system

Project type - new installation - first Selmo project

Special feature - modeled without previous PLC experience

VIBN - Process validated at an early stage

Result - Smooth commissioning on site

Scaling - Less dependence on experts

Result - Behavior was known before production start.

MAHLE filter systems Best_Practice_mahle_logo_01
Improved quality & simplified handling.
< a few weeks
From analysis to successful commissioning
AUTOMOTIVE - RETROFIT

Project - Test station (end-of-line tester) for quality control

Project type - Retrofit - Modernization of existing system

Preparation - Analysis of current status - Process recording

Process model - 2 sequences - 192 steps - 196 zones

IBN Duration - Fast implementation & optimization on site

Result - Higher quality, less complexity, faster cycle times.

AZO Group Best_Practice_azo_logo_01
Retrofit with maximum transparency.
< 80 h
Engineering effort for a complete plant modernization.
PLANT ENGINEERING - RETROFIT

Project - Modernization of an existing raw material handling plant

Project type - retrofit - existing plant

Approach - Process recorded on site and modeled in Selmo Studio

VIBN - Digital Twin of the 3D model

IBN Hardware - Beckhoff

Defined zones - 213

Engineering effort - 80 hours total

Result - Process was visible and verifiable before IBN. Optimizations already detected virtually.

thyssenkrupp AutomotiveBest_Practice_thyssenkrupp_logo_01
From idea to production in record time.
< 2 weeks
From the first workshop to live commissioning.
AUTOMOTIVE - PROOF OF CONCEPT

Project - Full automation of a camshaft assembly system

Project type - New system - Proof of concept

Preparation - 2 weeks preparation + 3 days on site

Process model - 7 sequences - 187 steps - 236 zones

VIBN - Validated before real IBN

IBN duration - 3 days full HMI commissioning

Result - Behavior was known before production start.
Austrian beverage producerBest_Practice_selmo_standard_logo_01
Full traceability of every batch.
100% traceability
For recipe, parameters and cycle.
FOOD & BEVERAGE - NEW INSTALLATION

Project - Digitalization of a juice mixing plant

Project type - New installation

Challenge - Manual process + BlackBox risk

Approach - WhiteBox logic

Monitoring - Every movement continuously recorded

Result - Flexibility + security + transparency
Cosma Engineering Best_Practice_magna_cosma_logo_01
Precision at top speed.
250 ms
Process accuracy in the high-speed range.
R&D - HIGH-SPEED PROCESS

Project - Intelligent press tool control

Project type - New system - R&D phase

Challenge - Extremely dynamic process

Precision - 250 ms cycle accuracy

Approach - Fully structured in Selmo

Result - Robust architecture without special code

 

Firmware test machine Best_Practice_selmo_standard_logo_01
Small in effort, big in results.
6 years
Without retraining or service call
TESTING EQUIPMENT - NEW INSTALLATION

Project - Test machine

Project type - First live use of Selmo Studio

Challenge - System could not be put into operation

Approach - Hardware + process precisely defined

IBN Duration - 2 days

Lifecycle - 6 years trouble-free

Result - "The machine explains itself."

 

Velox Werk GmbHBest_Practice_velox_logo_01
Stability in just a few days.
5 days -until full process logic is productive.
CONSTRUCTION MATERIALS - RETROFIT

Project - Retrofit of an automatic panel cutting system
Project type - retrofit - existing system
Approach - process recorded via video + e-plan
Process model - 20 sequences - 254 steps - 330 zones
VIBN - Completed before real IBN
IBN duration - TwinCAT 3
IBN duration - 5 days full process logic
Result - WhiteBox monitoring detected hidden sensor errors.



igm robot systems Best_Practice_igm_logo_01
Competence made scalable.
1 engineer - complete system modeled without classic PLC experience.
ROBOTICS - NEW INSTALLATION

Project - Robot welding system
Project type - new installation - first Selmo project
Special feature - modeled without previous PLC experience
VIBN - Process validated at an early stage
Result - Smooth commissioning on site
Scaling - Less dependence on experts
Result - Behavior was known before production start.



MAHLE filter systems Best_Practice_mahle_logo_01
Improved quality & simplified handling.
< a few weeks - from analysis to successful commissioning
AUTOMOTIVE - RETROFIT

Project - Test station (end-of-line tester) for quality control
Project type - Retrofit - Modernization of existing system
Preparation - Analysis of current status - Process recording
Process model - 2 sequences - 192 steps - 196 zones
IBN Duration - Fast implementation & optimization on site
Result - Higher quality, less complexity, faster cycle times.




AZO Group Best_Practice_azo_logo_01
Retrofit with maximum transparency.
< 80 h - engineering effort for a complete plant modernization.
PLANT ENGINEERING - RETROFIT

Project - Modernization of an existing raw material handling plant
Project type - retrofit - existing plant
Approach - Process recorded on site and modeled in Selmo Studio
VIBN - Digital Twin of the 3D model
IBN Hardware - Beckhoff
Defined zones - 213
Engineering effort - 80 hours total
Result - Process became visible and verifiable before IBN. Optimizations already detected virtually.

thyssenkrupp AutomotiveBest_Practice_thyssenkrupp_logo_01
From idea to production in record time.
< 2 weeks
From the first workshop to live commissioning.
AUTOMOTIVE - PROOF OF CONCEPT

Project - Full automation of a camshaft assembly system
Project type - New system - Proof of concept
Preparation - 2 weeks preparation + 3 days on site
Process model - 7 sequences - 187 steps - 236 zones
VIBN - Validated before real IBN
IBN duration - 3 days full HMI commissioning
Result - Behavior was known before production start.



Austrian beverage producerBest_Practice_selmo_standard_logo_01
Full traceability of every batch.
100% traceability
For recipe, parameters and cycle.
FOOD & BEVERAGE - NEW INSTALLATION

Project - Digitalization of a juice mixing plant
Project type - New installation
Challenge - Manual process + BlackBox risk
Approach - WhiteBox logic
Monitoring - Every movement continuously recorded
Result - Flexibility + security + transparency




Cosma Engineering Best_Practice_magna_cosma_logo_01
Precision at top speed.
250 ms
Process accuracy in the high-speed range.
R&D - HIGH-SPEED PROCESS

Project - Intelligent press tool control
Project type - New system - R&D phase
Challenge - Extremely dynamic process
Precision - 250 ms cycle accuracy
Approach - Fully structured in Selmo
Result - Robust architecture without special code



 

Firmware test machine Best_Practice_selmo_standard_logo_01
Small in effort, big in results.
6 years
Without retraining or service call
TESTING EQUIPMENT - NEW INSTALLATION

Project - Test machine
Project type - First live use of Selmo Studio
Challenge - System could not be put into operation
Approach - Hardware + process precisely defined
IBN Duration - 2 days
Lifecycle - 6 years trouble-free
Result - "The machine explains itself."



Our solutions

This is what the WhiteBox Experience looks like in practice.
WhiteBox = One Source of Truth: A single behavior model connects process, technology, interfaces, hardware and software into one shared source of truth.

01


Whitebox
Assessment

 

Evaluation of existing machine and process structures to determine the degree of transparency and the applicability of the WhiteBox principle.

 

02


PTF
Methodology

 

Define process - technology - function first. Create clear requirements before implementation begins.

03


Pilot &
Prototyping
 

 

Validate machine behavior with a prototype. Selmo Studio and Selmo HMI can be applied where appropriate to model, visualize and verify behavior. 

04


Virtual commissioning (vIBN) )

 

Test, validate and optimize behaviour in the digital twin before starting real hardware.

05


Real commissioning (IBN)

Faster ramp-ups with known behavior, lower risks and fewer surprises on site.

06


Scale &
Rollout
 

 

Reuse validated machine behavior across machines and sites. Reduce effort, ensure consistency and scale globally. 

Get in touch now.

 
Do you want to optimize your production, speed up projects or modernize systems?
Our experts will be happy to advise you.

Contact us now.

 
Do you want to optimize your production, speed up projects or modernize systems?
Our experts will be happy to advise you.