Manufacturing Simulation and Digital Twin Software

Streamline manufacturing operations with data-backed intelligence

Optimizing production processes to meet demand can strain resources and budgets. Digital Twin Studio^® supports your lines from raw material to finished goods with real-time, data-driven insights.

Digital Twin Studio^® Methodology: 4 steps to success

Manufacturing optimization software should make things easier, not harder. Digital Twin Studio^® takes a unique approach to guide you along the four essential stages of your digital transformation.

Modeling
Analysis
Optimization
Real-Time

Build a digital twin of your production system in weeks, not months

Model your production lines in the patented drag-and-drop environment of Digital Twin Studio® with intuitive auto-build features, a low-code interface, and a built-in library of 3D assets.

Emulate production data, routing, and schedules to leave no stone unturned

Simulate your production line with data from past shifts, upcoming demand forecasts, or seasonal production cycles. Visualize bottlenecks, backups, and delays with built-in reporting and lean analysis tools.

A patented neural network does the heavy lifting for full manufacturing optimization

Let Digital Twin Studio® automatically attack areas for improvement, or easily define and compare custom scenarios to optimize throughput, WIP, downtime, scheduling, and more.

Take things to the next level with real-time connectivity and machine learning

Digital Twin Studio® leverages real-time data, predictive analytics, and AI to continuously optimize operations, anticipating and resolving issues on the fly to keep your production lines running smoothly and efficiently.

Case Study: data-driven automation integration with Digital Twin Studio^®

Data-Driven Automation Integration with Digital Twin Studio

How Collins & Aikman reduced yearly costs by $160,000 with data-driven material handling optimization

Digital Twin Studio®: your All-in-One Manufacturing Optimization Toolkit

Smarter Factory Modeling

Build an accurate, scalable Digital Twin of your manufacturing facility in a matter of weeks. Our patented on-the-fly modeling captures everything from assembly lines to workstations, delivering a true-to-life representation that evolves with your processes.

Manufacturing Simulation & Lean Analysis

Leverage the advanced simulation capabilities of Simcad DT® to identify production bottlenecks, test different line configurations, and optimize process flow. Run 'what-if' scenarios to improve cycle times, reduce waste, and increase overall equipment effectiveness (OEE).

Integrated Production Data Emulation

Integrate real-time data from MES, ERP, and PLC systems to emulate your entire production environment. Analyze part routing, schedule adherence, and work-in-progress (WIP) management to ensure seamless manufacturing operations and efficient resource utilization.

Real-Time Plant Monitoring

Transform your factory Digital Twin into a live operational control center with Digital Twin Studio®. Connect to your shop floor data, monitor equipment status, maintenance cycles, track production KPIs, and visualize every stage of the manufacturing process with full analysis and reporting.

AI-Driven Process Optimization

Tap into our patented, built-in, neural network optimization to analyze production performance, predict equipment failures, and recommend adjustments. Use machine learning to automatically fine-tune operations, enhancing productivity and reducing downtime.

Predictive Forecasting & Real-Time Alerts

Stay ahead of production demands with dynamic forecasting, predictive analytics and automated alerts. Detect upcoming delays or equipment malfunctions and receive actionable recommendations that can be implemented immediately to maintain smooth, uninterrupted production.

DT Studio® Manufacturing ROI

12%

REDUCTION IN COST PER UNIT

INCREASE IN THROUGHPUT WITH SCHEDULING OPTIMIZATION

17%

MANPOWER HOURS SAVED/MACHINERY EFFICIENCY INCREASE

Managing production lines and inventory levels shouldn’t be a guessing game. Digital Twin Studio® provides real-time visibility from materials and supplies to equipment, helping you maintain optimal stock levels. Reduce costs and avoid production delays with smart, data-driven insights.

DT Studio® instantly provides, through integrated reporting and scenario analysis, feedback on efficiency gains at the point of attack, as well as how the change propagates throughout the system. With the bundled Simcad DT®, users can strategize how the operation will ramp up or down based on changes in demand, react to disruptions in supply, both planned and unplanned, and how changes in the product mix will impact the operation as a whole. Additionally, DT Studio® real-time digital twin benefits the user in terms of allowing for a multitude of changes to the system in a virtual environment where the user does not have the extensive costs associated with trial and error or the lengthy time-consuming process of utilizing excel sheets, for example.

Real-time digital twins in DT Studio® allow the user the opportunity to check and set optimal schedules, get live updates for increased control on productivity, as well as play out “what-if” scenarios to optimize resources, equipment, schedules and production. Dynamic simulation® allows the user to maintain relationships throughout the manufacturing, in order to better understand how different changes, affect the entire system. The user can also analyze possible differences in efficiency based on automation verses manual labor. The best path for production can be established, in order to increase productivity and reduce non-value-added time. And, utilizing Simcad DT®, all of this and more can be done, all without having to write code.

The DT Studio® Difference

Digital Twin Studio® brings operations into a virtual environment, taking away all the risk of costly experimentation. Strategic plans can be thoroughly tested and optimized before implementation. Dynamic Simulation allows the user to:

Detect bottlenecks and production delays

Schedule optimization and validation, using Kanban optimization and efficiency analysis - including dynamic spaghetti diagrams, Value Stream Maps, and congestion detection

Predicative Analytics

Predict how operations will be affected by changes in demand, disruptions in supply, changes in the product mix, etc. Check and set optimal schedules and receive live updates for increased productivity control

Powerful Reporting

Obtain integrated reporting and scenario analysis. Gather feedback on efficiency gains both at the machine- and resource-level and throughout the system

AI-Powered Efficiency

Analyze possible differences in efficiency based on automation versus manual labor. Establish the best path for production to increase productivity and reduce non-value-added time

Optimize Production Schedules

Balancing production demands and resources used to be a complex puzzle. Digital Twin Studio® simplifies it all. By blending real-time data, predictive analytics, and AI, you can optimize production schedules effortlessly. Less juggling, more efficient output.

Identify and Eliminate Bottlenecks

Automatically detect and resolve bottlenecks in your manufacturing process, keeping production lines moving smoothly and efficiently. Test and compare different production scenarios, allowing you to anticipate the impact of changes before implementing them on the floor.

Workforce Optimization

Scheduling and allocating your workforce used to be time-consuming. Now, Digital Twin Studio® forecasts labor needs based on real-time and historical data, optimizing shift planning and resource allocation. Keep your team productive and your operations efficient.

Maximize Machine Uptime with Predictive Maintenance

Unexpected equipment downtime throwing off your schedule? Not anymore. Digital Twin Studio® monitors machinery health in real-time, predicting maintenance needs before issues arise. Keep your equipment running smoothly and your production on track—no more surprises.

Improve Material Flow

Analyze and optimize the flow of materials through your plant, ensuring that the right materials are at the right place at the right time. Balance raw material and finished goods inventory levels with production needs, ensuring you have what you need when you need it without overstocking. Leverage historical and real-time data to minimize waste, ensuring that raw materials are used efficiently and sustainably.

Process Optimization and Quality Assurance

Maintaining top-notch product quality is crucial. With Digital Twin Studio®, you can monitor production quality in real-time, catching potential material defects or production bottlenecks early. Test improvements on the fly, and implement changes with confidence. Ensure every product meets your standards, keeping customers happy and reducing waste.

New Product Introduction

Launching new products often disrupts existing operations. Digital Twin Studio® lets you simulate new product manufacturing virtually, so you can refine and perfect processes before they hit the floor. Smooth launches with minimal risk—that’s innovation made easy.

Real-Time Monitoring & Alerts

Keeping tabs on every aspect of production can be overwhelming. Digital Twin Studio® offers real-time monitoring and instant alerts, so you’re always in the know. Stay ahead of issues before they become problems, ensuring your production runs like clockwork.

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CONTACT US

3909 75th St. Ste 105,
Aurora, IL 60504
(630) 851-9474
(630) 566-0756

ABOUT US

With over 30 years of industry experience, we are proud to support over 3,600 clients worldwide, helping them achieve sustainable competitive advantages through advanced digital twin technology.

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