During commissioning, the focus is on functional and quality testing of individual system components. Under time pressure, however, unexpected and non-reproducible anomalies in PROFINET communication often occur. This is not unusual, as shown by the “bathtub curve” in the graphic below. Still, the recurring question remains: Why now, when everything has already worked flawlessly before?
A high error rate at the beginning is not unique to electrical, mechanical, or network systems. It is a normal and necessary phase when transitioning a machine or plant into continuous operation and ensuring long-term availability. It only becomes problematic when this phase is unexpectedly prolonged - because device failures reappear at different points in the network over time. This is frustrating, time-consuming, and ultimately costly due to unexpected downtime.
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