As I near the completion of my final year project, it’s a good moment to step back and reflect on the process, the challenges I’ve faced, and the lessons I’ve learned while developing the digital twin of the Festo MPS station.

Technical Growth

This project has pushed me to deepen my understanding of key technologies in industrial automation. When I began, I had some familiarity with Siemens NX and TIA Portal, but combining them with PLCSIM Advanced and Node-RED for a fully integrated virtual commissioning and remote monitoring setup was a new frontier.

Working with Siemens NX Mechatronics Concept Designer taught me a lot about mechanical constraints, motion simulation, and signal mapping. Setting up rigid bodies, collision zones, joints, and sensors gave me insight into how even small misconfigurations can affect system performance and realism. Similarly, the experience with TIA Portal allowed me to improve my logic structuring and debugging skills through structured programming and function block development.

Node-RED was a new tool for me, and integrating it into the project for IIoT-based monitoring opened my eyes to the power of data visualisation in modern manufacturing. I now understand how data can be leveraged for decision-making beyond simple control tasks.

Challenges and Problem Solving

This journey was not without obstacles. Licensing issues with PLCSIM Advanced, simulation slowdown due to over-complicated collision detection, and a persistent gripper alignment issue tested both my patience and problem-solving skills. But each issue became an opportunity to learn—whether it was digging through Windows logs, rethinking component placement, or finding creative workarounds to simulate real-world behaviours.

One key takeaway here is the value of adaptability. I often had to revise my assumptions and pivot my design to find a more practical or robust solution. For example, adjusting the lid slide to simulate flexibility rather than trying to over-engineer a mechanical fix demonstrated how simulation design can reflect real-life behaviours in creative ways.

Project Management and Reflection

Throughout the project, maintaining a development blog helped me stay organised and track progress. It also gave me the opportunity to document technical decisions and rationale, which will be extremely useful for the final report.

Time management was challenging at times—especially with so many tools and systems involved—but creating a structured Gantt chart and regularly updating my workflow helped keep things under control.

Looking Ahead

This project has reaffirmed my passion for automation, simulation, and digital twin technologies. I now feel more confident in working with industrial software and systems, and I believe these skills will serve as a strong foundation as I pursue a career in smart manufacturing and control engineering.

I’m proud of what I’ve achieved so far and excited to continue refining the system and completing the final deliverables. While there’s still work ahead, particularly with Node-RED and system documentation, I’m already seeing the real-world relevance and scalability of what I’ve created.