Why is simulation one of the most important stages in automation design?

Every investment in automation involves decisions that affect production efficiency for many years to come. That is why, before the first part of a machine or production line is built, it is worth checking how the designed solution will function under real-world conditions. This is precisely what simulations and process modelling are for – they allow the design assumptions to be verified even before construction begins.

Why is the simulation stage so important?

Automation design does not end with the creation of a concept. Even the best-developed design requires verification to ensure that the assumptions made will actually work in practice.

Simulation allows the project to be transferred to a virtual environment and provides answers to questions that, at the documentation stage, remain mere assumptions.

Is the planned cycle time achievable? Will the robot have sufficient reach? Will the layout of the workstations ensure a smooth flow of material? Is the planned throughput realistic?

This enables decisions to be made based on data, rather than solely on experience or design assumptions, even before construction begins.

What can be verified through simulation?

Modern simulation tools allow you to analyse much more than just the layout of equipment.

Depending on the project, it is possible to check, amongst other things:

• material flow,
• cycle time,
• takt time,
• co-ordination between workstations,
• robot trajectories and reach,
• buffer capacity,
• internal logistics using AGVs and AMRs,
• the projected throughput of the entire line.

Such analyses enable the rapid identification of areas that could become bottlenecks in productivity even before the project goes into implementation.

Simulation helps to minimise investment risk

Any change made at the design stage is many times cheaper than modifying a completed production line.

That is why one of the greatest advantages of simulation is the ability to identify potential problems at a sufficiently early stage.

Most commonly, these relate to:

• an incorrectly designed layout,
• excessively long cycle times,
• buffering issues,
• limited production space,
• collisions between robots or equipment,
• inefficient material flow,
• excessively long start-up times.

Verifying these elements before construction begins significantly reduces the risk of costly changes in later stages of the project.

From model to actual production

Simulation is not merely used to verify the correctness of a design. It is also a tool that supports business decision-making.

Based on the modelling results, different investment options can be compared to assess which solution best meets the company’s objectives.
It will not always be a fully automated line.

Depending on the process, the best solution may turn out to be:

• a semi-automated workstation,
• upgrading an existing line,
• a change to the layout,
• introducing a robot only at a selected stage of the process,
• optimisation of internal logistics,
• balancing of production workstations.

It is precisely this ability to compare different scenarios that makes simulation one of the most important tools supporting automation design.

Nextomation: from concept to verified solution

At Nextomation, the design phase does not end with the development of a concept. Depending on the project’s requirements, we use simulations, analyses and feasibility studies to verify the assumptions made even before implementation begins.

This approach allows us to make data-driven design decisions, minimise investment risk and design solutions tailored to real-world production conditions.

See how projects take shape even before construction begins

Would you like to find out how process analysis, modelling and simulations help you make better design decisions?

Watch the interview with Krzysztof Gad, Head of the Concept & Technology Department at Nextomation, who explains what the concept phase involves and why good automation projects start with understanding the process even before implementation.

Watch the interview:

Planning an Automation Investment?

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Schedule a free consultation with the Nextomation engineering team. Together, we will analyse your case, identify potential risksand evaluate possible implementation scenarios.