Industrial simulation for processes, machines and people

With dynamic simulation we verify production, warehouse and logistics flows, with a virtual prototype the behaviour of a machine, and in virtual reality the training of people. All of it is built on a full-scale digital model of your operation that works with real data.

Three types of simulation

A mistake in the model costs a few clicks. A mistake in operation costs months and money.

Depending on what you need to verify, we choose one of three types of simulation. Often they are combined.

All three types share the same foundation: a full-scale digital model that works with your data.

01 · Processes

Dynamic simulation of production, warehousing and logistics

We test changes in production, warehousing, logistics or service systems in an accurate 3D model before you make them. The model works with real data, reveals bottlenecks and shows which variant of the system is the most efficient. You avoid costly management decisions.

Where dynamic simulation helps

Benefits of dynamic simulation

What will dynamic simulation reveal?

Every change in operation costs money. Simulation shows its impact in advance, based on data, not estimates.

  • 01

    Uncovering bottlenecks

    Experiments in the 3D model show where the flow gets stuck. We identify the causes and prepare an action plan of corrective measures.

  • 02

    Effects of product changes

    Planning to modify, extend, customize or replace components? We show how the change affects the production flow before you implement it.

  • 03

    Verification and design of layouts

    Changing the layout of the production area or designing a new one? We simulate all variants and measure which one is the most efficient.

  • 04

    Shift planning tool

    For production with variable inputs we build a parametric model. You always know the optimal number of resources, materials and workers per shift.

  • 05

    Simulation of critical scenarios

    Worker shortages, missing material, machine breakdowns. The model shows the impact of each situation and how to reduce it by reallocating the flow.

  • 06

    Optimization of production technologies

    Technologies and resources balanced to current and future production. Less waste thanks to a properly set flow and processes.

Digital model

What do you work with in simulations?

A simulation model captures the flow of products through the process chain in space and time. At every moment it knows the state of all products and operators. Data generated during the simulation reveal the efficiency of individual nodes of the system.

  • Workspace

    The model reflects the real placement and distances of elements, based on a floor plan extended with technologies, materials and workers.

  • Data inputs

    The flow through the model is driven by real data or qualified estimates. Operation times, tasks and transport match reality.

  • Simplified visuals

    Technologies are shown in a simplified form, which speeds up the build. Processes stay clear and system functions are preserved.

  • Relative time

    Processes run in real time, accelerated or slowed down. You can verify long time horizons as well as short fluctuations.

In the simulation model you compare variants in numbers, not estimates.

Linking space, data and time creates a digital model of the real system. You can run any test on it and see the consequences of every input and process. Once the model is continuously synchronised with operational data, it becomes a digital twin.

Process

How is a dynamic simulation created?

We build the model together with people who know the operation. That is the only way to get results you can trust.

  1. 1

    Analysis of the current state

    We understand the processes, flows and your needs.

  2. 2

    Layout design

    Together with an expert from your operation we create the basic layout of the system.

  3. 3

    Dynamic simulation

    We measure efficiency and reveal problems of the designed system.

  4. 4

    System tuning

    We minimize waste and maximize efficiency.

Before we start

What do you need to know for a simulation with valid results?

  • Process qualificationDescribed processes and flows, their inputs and consequences. Scenarios of states that can occur.
  • Needs and requirementsA clear goal. Which problem you want to solve or which processes to verify.

Tools

What software do you use for simulations?

We choose the tool by the question and combine it with our own components. Always aiming for the highest benefit relative to cost.

  • Processes

    FlexSim

    All-in-one simulation software. Simulation, analytics and optimization of production, warehouses and logistics in 3D.

    Learn more (CZ)
  • Physics

    AGX Dynamics

    Algoryx physics engine for faithful behaviour of machines, cables, ropes and contacts in virtual prototypes.

    Learn more (CZ)
  • 3D & data

    Unreal Engine + Datasmith

    A real-time engine for visualization and interaction. Datasmith converts 1:1 models from CAD and BIM software.

    About Datasmith
  • Integration

    MySQL + Express JS

    Our own components connecting the model to your data, APIs and web outputs.

Demonstrations of work in FlexSim (in Czech)

Full playlist
FlexSim simulation demo videoFlexSim simulation demo videoFlexSim simulation demo video

What simulation answers

Questions you should not answer by gut feeling. The model answers them with data.

Typical questions we solve with clients. Each leads to the area that answers it.

  • Is a new workstation worth it, or is rescheduling shifts enough?

    We run both variants against the same data and compare throughput and cost.

    Manufacturing simulation
  • How should racks be arranged to shorten travel?

    Simulating put-away and picking finds the layout with the shortest routes and sufficient capacity.

    Warehouse simulation
  • Will the machine handle the load, impacts and swinging loads?

    A virtual prototype with a physics engine verifies contacts, friction and cable behaviour before the first part is made.

    Virtual prototyping
  • How do we test machine control or autonomy without a physical prototype?

    The virtual prototype becomes a test environment for control software, sensors and machine learning.

    Virtual prototyping
  • How do we train operators without risk and without stopping the line?

    Workers repeat VR training as many times as they need, without endangering themselves or the operation.

    VR training
  • How do we practise a situation that cannot be staged safely?

    Fire, a fall from height or work on energized equipment can be tried in VR, where a mistake costs nothing.

    VR training

Data-driven decision making.
Test changes before you pay for them.

“Digital simulation lets you test everything virtually and avoid costly errors and delays.”

Describe what you want to change, verify or teach. We will suggest the type of simulation, the data it needs and what you can expect from the result.

Consultant, Vrealmatic
Consultant, Vrealmatic