Go to Homepage
EN

Planning and optimization of production sites

Simulation – optimal visualization for significant process improvement

Our simulations guarantee optimal work steps in the future. Visualization allows for problems to be detected early and material flow and processes to be optimized. What is the best way to set up the stations in a new factory? How can processes be optimized or the effectiveness of your production and utilization of your plant be increased? Our Automation & Engineering division supports you in the validation of your existing factory (brownfield) or the visualization of a completely new factory (greenfield).

Safe decision thanks to simulation

Through simulation, we know even before installation whether a plant will deliver the required performance. Bottlenecks in the plant are detected at an early stage and the technology can be adapted immediately to special challenges. The decision for a plant can be made on this basis in a competent manner, guaranteeing a safe investment. We have the necessary equipment, the best experts and programmers in this field as well as many years of experience from various large projects. From China to Europe to the United States, we are at your side to achieve the best possible result for your production line.

 

Compared to a static calculation of the process cycles, the dynamic simulation has a decisive advantage: It is very flexible! With a dynamic simulation, our programmers can, for example, precisely calculate the skid sequences and release production parts for the production line at the appropriate moment to achieve maximum utilization. This results in an optimal process and material flow for you. Additional benefits: the work of quality management is facilitated, wear and tear figures are reduced and costs are significantly lowered.

Develop concrete added values

Working closely with our customers, we can create a detailed and accurate simulation of your factory. This 3D animation is an exact replica of reality, which is used as a basis for optimizations. We respond to your wishes, implement them together and deliver exact results through close exchange.

Our experts not only help you with the visual implementation, but also advise you on possible changes and bring in new ideas to optimize your work processes. So, you not only get a 3D version of your factory, but at the same time advice on process optimization and improvement of your factory planning.

In 5 steps to simulation

When planning a new factory or integrating new processes, the first thing to do is define the framework conditions and goals. What result do you want to achieve and how can we support you in the best possible way? Together we develop a common understanding of the project, which determines the goals, requirements and expectations. In addition, the existing equipment and processes are assessed and incorporated into the new layout planning. We also advise you on the latest technologies and what advantages they can bring to your production line.

 

The second step involves creating a replica of the factory or the existing processors in special software. This digital twin of the conditions on site makes it possible to quickly assess which parameters need to be changed. Based on this overview, our experts assess how the existing system is working. Process steps are analyzed that could possibly develop into problem areas later on.

 

This allows for validation or optimization of the system to be tackled in the next phase. A subsequent test determines how much impact the planned optimization will have for the company. For example, the cycle time of a cycle can be optimized from 120 seconds to 60 seconds.

 

  • Step 1: Definition of the framework conditions and goals
  • Step 2: Assessment of the already existing plants and processes
  • Step 3: The findings obtained are incorporated into layout planning
  • Step 4: Creation of a digital twin of the factory
  • Step 5: Validation or optimization of the system

Potential recognized – and then?

Of course, we are also there to support you beyond pure simulation. For example, our experts deal with the risks involved in using multiple robots and make recommendations on what to do in the event of a failure. Other topics include the use of additional equipment to optimize processes or avoid risks. In addition, we also take over the realization and start-up support of the optimizations through the implementation of automation solutions or IT-based optimizations.


Leadec Automation & Engineering GmbH

 

Meitnerstraße 11
70563 Stuttgart

You might also be interested in:

All
  • Assembly Planning

    We at Leadec can effectively support you in product and process planning as well as optimization in both areas. Our experts develop innovative solutions for your series and assembly planning in a goal-oriented, resource-saving and efficient manner.

  • Factory Planning

    With experience from numerous projects worldwide, we are experts in both new factory construction (greenfield) and factory planning for existing production buildings (brownfield) to integrate new facilities or production lines.

  • Production Optimization

    You want to increase your efficiency and raise the output of your production line? Do not worry about unnecessary expenses! We at Leadec suggest specific solutions how you can increase your production optimization to save time and costs.

FAQ

What kind of simulations are there?

There are different types of simulations. One distinguishes between static, Monte Carlo, dynamic, continuous, discrete, hybrid, system dynamics and multi-agent simulation. Since everything at Leadec revolves around your factory, our experts use static simulation, in which a snapshot of a specific point in time is presented. In dynamic simulation, the processes relevant to your production are simulated and considered. Discrete simulation is also used. This is also referred to as sequence simulation or event-driven simulation. The elements represented in this simulation can be standardized with random numbers, queues or probability distributions. In this way, various processes can be simulated, including their effects on production.

Which programs are used for simulation?

The common programs are DGN, DXF, DWG, Step, Parasolid, IGES, JT, NX (PRT) or CATIA V4+V5 (CATProduct, CATPart). Our experts are able to optimally adapt to your preferred program based on their experience. 

What are the advantages of simulations?

  • Existing plants and processes are examined and included in the new layout planning
  • Advice on the latest technologies and what advantages they can bring to your production line
  • Sales are accelerated
  • Flexible planning
  • Expensive errors are avoided

What knowledge is gained from the simulation?

The simulation obtained can be used as a basis for optimization. In addition, our experts will advise you on possible changes and contribute new ideas for optimizing your work processes. So you not only get a 3D version of your factory, but also advice on process optimization and improvement of your factory planning at the same time.