Definition
Factory simulation is a virtual model of your production system used to test flow, resources, and control logic before changes are made in the real plant.
Teams use it to compare scenarios, quantify risk, and make faster layout or process decisions with less downtime.
Where It Delivers ROI
The strongest use cases are new line design, capacity planning, bottleneck analysis, and virtual commissioning.
The value is highest when the same model is reused across planning, engineering, and continuous improvement cycles.
- Reduce commissioning surprises by validating edge cases early
- Test staffing and shift assumptions without interrupting production
- Prioritize investments with throughput and OEE impact estimates
How to Start
Begin with one line and one business question, such as where the true constraint is during peak demand.
Establish a baseline model, validate with historical data, then run scenario comparisons with clear decision criteria.