Abstract: A real process is simulated for preventively detecting the need for maintenance and the simulation is synchronized with the real process. Malfunctioning can be timely detected from a process control viewpoint by comparing the real process with the simulation and maintenance measures can be appropriately managed. Downtime in a facility can thus be reduced and individual process steps are optimized.

Abstract: In order to automatically generate simulation programs, basic program operations of a real program are made available in the recipe management. Furthermore, process parameters of the real process are made available in the sequence logic (SFC). The basic program operations are automatically linked to the process parameters in order to simulate the method, whereby a simulation model is generated that is initialized according to the real process. Method simulation is advantageously controlled simultaneously by the process control system of the real process. Parallel running of the real process with the simulation process enables effective monitoring and improved maintenance management.