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New and unprecedented changes in customer demands, globalization, cost pressures, innovative product development strategies to shorten product development time, and changing external landscape with reduction of trade barriers, poses challenges and opportunities for the manufacturing industry. Customer demands and needs require modification and reconfiguration of existing manufacturing and assembly plants as well as creation and setup of new ‘Greenfield’ facilities in developing countries. Currently, the solutions provided by most service providers focuses on limited elements of the solution methodology. We have developed an integrated methodology to perform virtual plant commissioning using digital manufacturing, design for six sigma and lean manufacturing principles.