Simulations – A Method for Improving Production Process Parameters

27.01.2025

Optimizing the operation of a plant used to involve testing new solutions directly on functioning production lines. This not only consumed time but also carried the risk of downtime and associated losses. Today, thanks to digital technologies and simulations, the optimization of production processes is faster, easier, and more effective.

Advanced production process simulators, available to industrial enterprises across various sectors, enable virtual modeling of real systems and analyzing processes in a safe, digital environment. Companies considering changes can test various scenarios without interfering with existing production lines. By leveraging digital twin technology, modeling becomes precise and dynamic, accurately replicating production conditions.

How a Production Process Simulator Works

How does a simulator operate? Such a system uses input data like machine layouts, cycle times, material flows, and human resources to create a virtual model of the process. It can function in real-time or at an accelerated pace, allowing analysis of both current and long-term operational scenarios. Its capabilities are user-friendly, with an intuitive interface enabling adjustments to process parameters, different machine configurations, testing new schedules, or simulating the impact of unforeseen events such as delivery delays or breakdowns.

One of the key applications of simulators is identifying bottlenecks that limit process efficiency. Virtual models can pinpoint problematic areas and test solutions before implementation. They also offer valuable opportunities for resource optimization, from materials to workforce schedules. Consequently, companies can plan activities precisely, minimize waste, and enhance efficiency.

Various Applications of Simulators in Industry

Simulations enable rapid adaptation to changing market conditions. In a virtual environment, companies can test different production scenarios to meet new demands without halting current operations. For businesses, this flexibility translates into greater operational agility and competitive advantage. Simulations are also invaluable for investment decision-making. Before purchasing new equipment or upgrading existing production lines, companies can virtually test potential configurations, evaluating their impact on efficiency and operational costs. Reducing design errors is a critical benefit, significantly lowering implementation costs.

What does this mean in practice? Examples abound. In the chemical industry, for instance, the operation of resin condensation systems can be simulated, including recipe creation and modification interfaces. This approach allows adjustment of installation parameters, error elimination, and reduced material waste during system startup. Additionally, integrating the simulator with the production system enables employee training for swift problem-solving, significantly enhancing safety and operational efficiency.

Simulators have equally broad applications in logistics, the food industry, and pharmaceuticals. In logistics centers, simulations of automated sorting systems and AGV trucks allow testing system efficiency under varying loads and practicing responses to failures like line stoppages or vehicle malfunctions. In the food sector, simulating the operation of filling, labeling, sealing, and packaging transport machines enables throughput analysis, bottleneck identification, and material waste reduction. Similarly, in pharmaceuticals, a simulator for mixing and filling systems supports testing various formulas and process parameters in digital conditions, avoiding costly ingredient waste.

Harness the Potential of Simulators in Your Business

Modern simulators, equipped with advanced analytical functions, make drawing actionable conclusions effortless. Key metrics like OEE (Overall Equipment Effectiveness) provide essential insights into resource utilization. Analyzing OEE helps pinpoint areas requiring optimization, such as downtime, machine operating speeds, or product quality.

At Control-Service, we leverage our extensive experience in simulation to support businesses in their pursuit of operational excellence. Using advanced tools, we assist clients in analyzing, optimizing, and innovating their production processes. Collaborating with industry leaders, we deliver solutions tailored to unique needs.

Do you want to achieve better results and build a competitive edge in a demanding market? Let’s collaborate.