Large steel construction plant — production scheduling & digital twin
Each construction order has unique production steps and routing. The AnyLogic model integrates live ERP data, runs probabilistic simulations, and generates the daily production schedule — reducing on-time delivery failures by 35%.
Digital Twin & Production PlanningAGV fleet optimisation — fleet size, speed & working hours impact on throughput
Simio simulation of AGV operations in a production site. Products progress through various facilities before being transported by AGVs to later destinations. The model evaluates multiple scenarios to quantify how fleet size, operational speed, and daily working hours affect throughput — providing actionable insights for right-sizing AGV resources with minimal waste.
AGV & Logistics OptimizationManufacturing line — AGVs supplying assembly stations
Comprehensive workflow simulation: AGVs delivering full boxes to assembly lines, collecting empties, returning to loading area. Model provided actionable insights on AGV deployment to ensure cost-effective and efficient operations.
AGV & Logistics OptimizationAutoStore-type warehouse — trolley & robot performance optimisation
Simio model replicating AutoStore warehouse operations — picking, digging, moving, dropping. Detailed visualisation of trolley movements and all associated processes. Analysis of key component interactions to improve throughput and efficiency.
AGV & Logistics OptimizationAutomated pallet warehouse — shuttle & lift coordination with WMS
Visual Components model replicating automated warehouse operations with storage positions, lifts, and conveyors. Detailed visualisation of pallet movements, lift cycles, and shuttle sequences. Identified the optimal configuration to meet throughput SLAs.
AGV & Logistics OptimizationAutomotive welding cell — virtual commissioning, PLC validation
Visual Components model connected to real Beckhoff TwinCAT PLC program via ADS. Every production sequence, safety interlock, and fault mode tested in simulation. 11 logic errors found before site. Physical commissioning 60% shorter.
Virtual CommissioningBiscuit production line — delta robot pick rate optimisation
Dynamic pick algorithm simulation allocating biscuits to delta robots based on position, speed, and arm availability. Target throughput achieved with 2 fewer robots than initial design. Zero arm interference at maximum conveyor speed.
3D Robot & Facility SimulationFull factory layout — material flow, robot reach & throughput analysis
Complete 3D facility model covering robot cells, conveyors, assembly stations, and logistics flow. Layout alternatives compared for throughput per unit of floor space. Offline robot programs exported for all robots in the facility.
3D Robot & Facility SimulationMulti-line manufacturer — bottleneck analysis & capacity planning
Simio model of a complex multi-line production environment validated against 6 months of historical data. True system capacity found 18% higher than management estimate. Two critical bottlenecks identified — neither was on the original improvement list.
Process & Production SimulationStochastic production model — scheduling with random failures & variability
Simulation with stochastic process times and random resource failures across all stations. Multiple scheduling scenarios compared — showing how each policy performs under variability. Probabilistic order completion rates calculated per scenario.
Digital Twin & Production PlanningAssembly cell — OPC UA connection to Beckhoff TwinCAT PLC
Visual Components model connected to Beckhoff PLC via OPC UA. Full sequence testing of a pick-and-place assembly cell including error states and recovery logic. Robot programs generated offline — no manual teaching required on site.
Virtual CommissioningSystem integrator tender — 3D sales demo delivered in 8 days
Visual Components animation of a welding cell proposal built in 8 days before a tender deadline. Competitors submitted drawings; the integrator submitted a 3-minute HD walkthrough. Customer feedback: "the video made the decision easy."
Sales Support 3D DemosLarge warehouse — forklift fleet sizing across receiving, picking & storage
Simio model handling over 20,000 boxes through receiving, storage, and picking zones. Fleet size scenarios tested against shift demand profiles. Result: 2 fewer forklifts than initial estimate, with all throughput SLAs maintained. Charging schedule optimised as a by-product.
Warehouse Fleet SimulationAMR fleet — three-task cycle with collision avoidance & deadlock resolution
Simio simulation of autonomous mobile robots performing box loading, machine delivery, and empty return cycles. Dynamic collision avoidance and deadlock resolution logic validated before hardware deployment. Dispatch rules confirmed — fleet size reduced from 8 to 6 units.
Warehouse Fleet SimulationAutomated wall assembly line — robot kinematics & laser cutting validation
Visual Components model replacing static CAD for a prefabricated wall assembly system. Laser cutting sequences, part movements, and robot kinematics simulated before build. Three layout changes identified and resolved before any steel was cut — saving 4 weeks of rework.
3D Robot & Facility SimulationCar manufacturer — digital twin of assembly area for continuous throughput improvement
Live-connected AnyLogic digital twin for an automotive assembly area. Real production data feeds daily model updates. Gantt charts and KPI dashboards used by shift managers to identify flow disruptions before they affect output. Assembly throughput improved 12% over 6 months of continuous use.
Digital Twin & Production PlanningASRS new build — row/level configuration & loading strategy optimisation
Simio simulation framework for a new automated storage and retrieval system, determining the optimal row and level configuration before construction. Three loading and unloading strategies compared across realistic demand profiles. Final configuration saved 2 aisles versus the vendor's standard proposal.
Warehouse Slotting & LayoutOverhead trolley system — speed, fleet size & shift pattern optimisation
Simio model of a modular overhead track system analysing the interaction between trolley speed, fleet size, and working hours on production throughput. Data showed that a speed increase outperformed fleet expansion 3:1 in cost-effectiveness — avoiding a significant capital purchase.
Warehouse Fleet SimulationManufacturing plant — inbound & outbound logistics with buffer dimensioning
Simio model integrating daily operational data to replicate real-time conditions at a manufacturing plant. Buffer dimensioning, conveyor settings, and portal operations dynamically adjusted per current orders. Identified the configuration that eliminated a recurring outbound bottleneck without additional dock doors.
AGV & Logistics OptimizationPlant-wide digital twin — production & logistics simulation
Enterprise Dynamics model covering an entire plant: orders, resources, workforce, warehouses, and transport (AGVs/AMHS). Data-driven and highly parametrised design allows realistic scenario testing, bottleneck analysis, and system improvement. Advanced animation makes complex interdependencies intuitive for stakeholders.
Supply Chain SimulationMilitary equipment manufacturer — digital twin for production planning
Simio digital twin of a military equipment production facility. Live model connected to production orders and resource constraints — used for scheduling, capacity analysis, and on-time delivery forecasting across a complex, low-volume high-mix production environment.
Digital Twin & Production PlanningNo examples match this filter combination.