Effective Automation System Commissioning: From Automotive to Intralogistics

Automation system commissioning, both in the mature production environments of the automotive industry and in the rapidly evolving intralogistics sector, has long gone beyond basic technical testing. Today, it is a complex process combining automation, IT, and work organization, directly impacting the efficiency, safety, and flexibility of modern logistics centers.

In recent years, the commissioning of automation systems in intralogistics has undergone a significant transformation. Modern warehouses and logistics facilities now require not only efficient system start‑up, but also full integration with management systems (WMS, ERP), optimization of material flows, and the ability to respond flexibly to changing operational conditions.

As a result, automation system commissioning has become a strategic element, combining technical, organizational, and digital aspects, with a role that extends far beyond traditional equipment testing. Experience gained over many years in commissioning automotive assembly lines is increasingly becoming a point of reference for intralogistics projects facing growing system complexity and IT integration challenges.

Automotive vs. intralogistics – two worlds of automation, different challenges

Commissioning automation systems in the automotive industry and intralogistics serve similar fundamental objectives: ensuring smooth operation, optimizing processes, and minimizing downtime. In practice, however, these two environments differ significantly.

Continuity and repeatability in automotive

Assembly lines in the automotive industry require exceptional repeatability and precision in the production of individual components, with highly rigid commissioning schedules. The assembly process is continuous and sequential, based on precisely defined OEM standards. Each stage directly affects the next, and the entire line operates as a single mechanism, utilizing robots, tightening systems, presses, and vision systems under the supervision of quality control systems.

Achieving stable production takt and minimizing errors and downtime is critical, as both have a direct impact on costs. Process stability and compliance with standards such as ISO, VDA, MSA, or SPC are fundamental requirements.

Flexibility and integration in intralogistics

In intralogistics, processes are far more dynamic and variable, with material flows driven by current orders and warehouse strategies. Systems must handle a wide range of products and scenarios while seamlessly integrating with higher‑level systems such as WMS and ERP.

The objective of commissioning is not stability alone, but above all ensuring adequate throughput of transport lines, optimizing material flow paths, synchronizing data in real time, and enabling scalable operations as volumes change.

Scope of commissioning tests – what determines system readiness

The scope of tests performed during automation system commissioning varies by industry, although the overarching goal remains the same: confirming that the system is ready for safe and efficient operation.

Testing in automotive

In the automotive industry, testing includes comprehensive machine and process validation, covering:

• safety and technical readiness,
• machine and process capability (MSA, Cm/Cmk, Cp/Cpk),
• functional equipment testing and product validation,
• run‑off, dry‑run, and Run at Rate testing,
• traceability, Poka‑Yoke solutions, and ergonomics,
• process and logistics robustness testing.

Testing in intralogistics

In intralogistics, testing focuses on:

• technical readiness (OHS, infrastructure),
• internal transport testing (AGV, AMR, conveyor systems),
• material flow and order picking tests (picking, put‑to‑light, weight checks),
• integration with WMS systems and traceability,
• performance testing (Run@Rate),
• emergency scenarios, recovery procedures, documentation, and audit tests.

Team competencies and documentation – key organizational differences

Clear differences can also be observed in team structures and required competencies. In automotive projects, commissioning is handled by teams of mechanics, robotic engineers, and quality and safety specialists with deep expertise in assembly technologies and automation.

In intralogistics, close cooperation between automation engineers, IT teams, system integrators, electricians, and mechanics is essential. Key competencies include industrial networks, PLC configuration, and integration with higher‑level systems. In practice, this requires interdisciplinary teams combining industrial automation expertise with strong IT skills.

Documentation also differs in scope. In automotive, it is extensive and includes quality procedures and OEM compliance audits. In intralogistics, documentation focuses primarily on network topology, system configuration, and the safety of material flows.

Pillars of effective automation system commissioning in intralogistics

Commissioning complex industrial automation systems requires not only specialized technical expertise, but also solid organizational preparation, effective communication, and close cooperation between teams. Every stage – from documentation analysis to final performance testing and fine tuning – has a direct impact on project success.

1. Team onboarding and training 

The first pillar is onboarding and training, ensuring familiarity with standards and know‑how from the very beginning of the project. Internal and external training covers controllers, drives, inverters, and industrial networks. Required certifications – software‑related (e.g. safety PLC), hardware‑related (electrical licenses), and workplace‑specific – should be secured early.

Equally important is creating a shared knowledge platform that collects experience from completed projects and is continuously updated.

2. Team planning and work organization 

Effective team planning involves optimizing headcount at each project stage and clearly defining roles and responsibilities. Attention to work‑life balance, especially in the context of business travel, supports long‑term team motivation.

3. Client–supplier cooperation and team integration 

Effective cooperation requires a shared working environment that includes technical documentation, progress tracking tools, planning mechanisms, and change management processes. Clear priorities and milestones are essential.

Automation engineers often act as a bridge between electricians, mechanics, designers, and IT and WMS teams, which requires not only technical expertise, but also strong communication skills and adaptability in a dynamic environment.

4. Documentation analysis and commissioning preparation 

The commissioning process begins with analysis of documentation and software. Network topology and electrical schematics are verified, while necessary tools for on‑site work are prepared in parallel. Depending on the construction phase, adequate on‑site facilities must also be ensured.

5. Technical, integration, and performance testing

Initial on‑site activities include verification of hardware and software topology, input/output checks (IO check), and documentation updates. This is followed by safety testing, manual and automatic tests, system pre‑configuration, and integration with WMS.

Performance tests (Run@Rate) and product‑based tests allow assessment of system operation under conditions close to real production.

6. Fine Tuning and system stabilization 

The final stage is Fine Tuning, involving observation of system behavior, identification of issues, and implementation of necessary adjustments. This is the phase in which the system achieves its target stability and performance.

Expert insights from real‑world projects

“A key element of every commissioning process is well‑prepared technical documentation and control over its current version. A common problem is teams working with outdated or inconsistent documents. Proper change control helps avoid issues. More difficult to detect are errors in the design documentation itself – everything appears to work, but not as intended. This is why more companies are using version control systems for both software and project documentation, enabling faster diagnostics and increasing overall commissioning reliability” – says Damian Tomasiak, Senior Control Systems Engineer, Sii Poland

“In recent years, the approach of intralogistics companies to project commissioning has changed significantly. This has been driven by factors such as geopolitical shifts like Brexit, which limited access to skilled engineering resources, rising travel and logistics costs, and rapidly changing project schedules. All of this has accelerated the search for solutions that reduce on‑site commissioning and testing time.

Technology development has played a key role here. Most leading intralogistics companies now invest in virtual commissioning based on digital models before on‑site testing begins. In addition, modern automation control methods enable fast programming and a high level of standardization, significantly shortening commissioning time.

These two directions – solution standardization and virtual commissioning based on the digital twin concept – define current trends not only in intralogistics, but across many industrial sectors” – comments Tomasz Panko, Senior Director Controls Engineering EMEA, Swisslog

If you are planning to commission or modernize automation systems, it is worth relying on teams with experience in delivering similar projects on an international scale. Sii Poland combines know‑how gained in automotive projects with the flexibility required in intralogistics, supporting clients in safe and efficient automation system commissioning.