AGV logistics warehouse simulation — automated guided vehicle routing optimization
Logistics optimization

How many AGVs do
you actually need?

Stop over-buying vehicles and under-specifying routes. We simulate every configuration before a single purchase order is raised.

Typical result: 20–35% fewer vehicles than initial estimate
Explore logistics simulation →
Production process simulation — manufacturing throughput bottleneck analysis
Production simulation

Find bottlenecks
before they cost you.

Model your entire manufacturing line end-to-end. Test improvement ideas safely — without disrupting live production.

Typical result: 15–40% throughput improvement identified
Explore production simulation →
3D robot simulation in Visual Components — robot arm programming and virtual commissioning
3D robot & facility simulation

Commission your
robot cell digitally first.

Validate PLC software, robot programs, and facility layouts in a full 3D virtual environment — before the hardware arrives.

Typical result: 50–70% shorter physical commissioning time
Explore 3D simulation →
Digital twin production planning — live ERP scheduling dashboard and optimization
Digital twin & scheduling

Your production plan,
updated every morning.

A live digital twin connected to your ERP generates probabilistic daily production schedules — automatically, every single day.

Typical result: 30–40% improvement in on-time delivery
Explore digital twin planning →
1 / 4

Sound familiar? These are exactly the problems we solve.

You don't have to commit capital and find out it doesn't work. There's a better way.

01

Expensive surprises after go-live

New lines or warehouses underperform because component interactions were never tested together.

02

Planning runs on spreadsheets

Static Excel scheduling can't handle machine failures, staff shortages, or demand spikes. You're constantly firefighting.

03

AGV and robot sizing is guesswork

Over-buying is costly. Under-buying creates bottlenecks. Without simulation you're estimating, not deciding.

04

PLC code validated too late

Software bugs found during physical commissioning cost weeks of delay and expensive floor-time from engineers.

What we do

Six services, one goal:
de-risk your decisions

Technology-agnostic — we choose the best tool for your problem: Visual Components, Simio, AnyLogic, Enterprise Dynamics, or IBM.

3D robot simulation model in Visual Components — robotic arm in factory layout

3D Robot & Facility Simulation

Build a virtual replica of your production cell, assembly line, or entire facility. Test robot programs, layouts, and throughput before metal is cut.

Visual ComponentsOPC UATwinCAT
Learn more
Simio production simulation model — manufacturing process bottleneck analysis

Process & Production Simulation

Model your process end-to-end. Find bottlenecks, test what-if scenarios, and arrive at optimal configurations — without disrupting live operations.

SimioAnyLogicEnterprise Dynamics
Learn more
Digital twin production scheduling — live ERP-connected daily planning dashboard

Digital Twin & Production Planning

Live simulation connected to your ERP or MES. Automated daily schedules that account for variability, failures, and demand changes.

SimioERP integrationMES integration
Learn more
AGV warehouse optimization simulation in Simio — automated guided vehicle fleet sizing

AGV & Logistics Optimization

Right-size your AGV fleet, ASRS configuration, and warehouse routing. Optimal number, speed, and movement patterns before hardware spend.

SimioIBM Optimization
Learn more
Sales support 3D simulation demo — interactive automation visualization for clients

Sales Support 3D Demos

Win more deals by showing clients your automation solution in interactive 3D — before you've built anything. Turn proposals into visual experiences.

Visual Components3D animation
Learn more
Simulation training courses — Visual Components, Simio and AnyLogic workshops

Training & Consulting

Expert-led courses in Visual Components, Simio and AnyLogic. Online or on-site, beginner to advanced, at your own pace.

Visual ComponentsSimioAnyLogicGanttplan
Learn more
Why it matters

The cost of not simulating is always higher

2006
Founded — 20 years of industrial simulation expertise
1000+
Pre-built robot models in Visual Components library
12+
Countries served remotely — USA, Sweden, France, Denmark, Portugal & more
Our process

From question to confident decision in weeks

1

Discovery call

Share your challenge. We identify the right approach and toolset — no commitment required.

2

Tailored proposal

Scoped model, timeline, and fixed-price deliverables. Typical projects: 4–12 weeks.

3

Model development

Built with your real data — floor plans, process times, ERP order books. Validated iteratively.

4

Insights & handover

Clear results, all scenarios documented. Model yours to keep for ongoing use.

AI-assisted modelling

Start before you have all the data

We use AI to generate synthetic input data for new layouts — AGV travel times, production cycle distributions, facility parameters — so simulation studies can begin at concept phase, before measurements exist. Real data replaces synthetic inputs as it becomes available.

How AI is used in our simulation work →
Data generation
Synthetic AGV, forklift & layout data for new facilities
Python + Simio
AI-written batch scripts automate scenario runs and reporting
Faster studies
3–5 engineering days saved on data preparation per project
Featured service

Your production plan,
every morning, automatically

Digital twin production scheduling — Simio dashboard with ERP-connected daily plan

Digital twin
production planning

A simulation model connected live to your ERP reads current orders, resources, and constraints — then generates a probabilistic daily production schedule each morning, automatically.

  • Calculates probability of on-time delivery for every order
  • Flags high-risk orders before they disrupt the floor
  • Accounts for machine failures, staff absence, and variability
  • Supports reverse planning and manual overrides
  • Works with SAP, custom MES, and proprietary databases
Ask about digital twins →
Case studies

Real problems, real results

Each project delivers a specific, measurable outcome. A few examples:

AGV and ASRS warehouse optimization simulation in Simio
Logistics · Simio

AGV & ASRS optimization — e-commerce warehouse

Three fleet configurations modeled before any procurement decision. Optimal number, speed, and routing patterns identified from simulation data alone.

28% fewer AGVs needed than initial estimate
AnyLogic production scheduling simulation for large steel construction manufacturing plant
Manufacturing · AnyLogic

Digital twin scheduling — large steel construction plant

Live ERP-connected simulation generates daily production schedules with probabilistic risk analysis for complex, unique orders with hundreds of dependencies.

35% on-time delivery improvement within 3 months
Visual Components 3D robot simulation for automotive welding cell virtual commissioning
Robotics · Visual Components

Virtual commissioning — automotive welding cell

PLC programs validated in 3D simulation before physical installation. All software bugs found and resolved in the virtual environment before go-live.

60% shorter commissioning — zero software issues on go-live
View all examples →
Free guides

Understand the tools before you commit

Plain-language guides written for engineers and project managers — no vendor spin.

Logistics

How many AGVs does your warehouse actually need?

Why formulas fail and how simulation finds the right fleet size before procurement.

Read guide →
Robotics & Automation

What is virtual commissioning — and when does it pay off?

How VC works, what software is involved, and the ROI calculation.

Read guide →
Planning

Digital twin or simulation — which does your project need?

A plain-language comparison to help you choose the right tool for your project.

Read guide →

Certified partner & reseller of leading simulation platforms

Visual Components · Simio · AnyLogic · Dualis / Ganttplan
What clients say

Trusted by engineers and decision-makers

"

Great work on the simulation. I was very impressed with the product. It's very good!

Client reference — available on request
"

In direct comparison with other suppliers, SimulateFirst stands out for its extraordinary commitment and expertise. We strongly recommend them as a partner.

Client reference — available on request
"

The tools used at SimulateFirst allow rapid processing without sacrificing detailed data. Smart brains — they know very well how simulation software works.

FAQ

Common questions before getting started

Most projects run 4–12 weeks depending on complexity. A focused AGV sizing or bottleneck study: 3–4 weeks. A full ERP-connected digital twin: 8–16 weeks. We scope this precisely before any commitment.
We work under NDA as standard. Process times, floor plans, order volumes, machine parameters remain confidential. All models and data are handed over to you at project end.
Yes — ERP and MES integration is a core capability. We have experience with SAP, custom MES systems, and proprietary databases. The digital twin reads live data automatically to keep schedules current.
We've delivered full projects entirely remotely for clients in the USA, Sweden, France, Denmark, Portugal and beyond. For robot simulation, CAD data is typically enough. Many clients prefer remote delivery for speed and cost.
Mid-size manufacturers through to tier-1 automotive and global logistics operators. The common thread: a specific decision to de-risk. If the cost of getting it wrong exceeds the simulation cost, it makes financial sense.
The model is yours. We hand over all files with documentation. Many clients take our training courses in Visual Components, Simio, or AnyLogic to build lasting simulation capability in-house.
Meet us in person

Upcoming events

16–18 Mar 2027

LogiMAT, Stuttgart

Hall 4, Booth A02

20–24 Apr 2026

Hannover Messe

Hall 15, Booth H55 — Digital Twin & AI

2026 — flexible

Simio Training 2026

Contact us for dates

Free consultation

Let's talk about your project

Tell us your challenge. We'll tell you honestly whether simulation is the right tool — and if so, which approach. No obligation, no sales pressure.

Response within 1 business day
Full NDA available as standard
Remote delivery worldwide
Transparent fixed-scope proposal

Germany — Dresden

Anton-Graff-Str. 24, D-01309
dresden@simulatefirst.com
+49 (0) 351 30906020

Poland — Wroclaw

ul. Powstancow Slaskich 5, 53-332
polska@simulatefirst.com
+48 75 6406434

We respond within 1 business day · NDA available · No spam, ever

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