Industrial systems simulation

Industrial systems simulation is the process of creating and using anintegrated, executable digital model or virtual representation of a real‑world industrial system, such as machines, production cells or lines, process plants, factories or logistics facilities. Simulation allows engineers to evaluate and optimize designs and perform virtual commissioning before physical implementation. Additionally, users across engineering and operations can leverage the digital twin of industrial systems to optimize their production throughout the lifecycle or to train workers and operators in a safe, virtual environment. Overall, industrial systems simulation helps companies improve productivity, reduce costs and make more informed decisions by providing a risk‑free environment to experiment with various system configurations and operating strategies before and during real‑world deployment.

Industrial systems simulation is a powerful solution that can benefit various industries, including:

• Automotive: Helps expedite launches and line-changeovers and maximize resilience in the face of shifting demands and manufacturing disruptions.
• Industrial machinery: Helps design and validate complex industrial systems such as production lines, ensuring seamless integration and maximizing efficiency.
• Pharma: Enables scale-up and tech transfer by predicting product quality attributes in commercial-scale equipment based on lab-scale data, and helps perform virtual commissioning to ensure proper functioning of the automation design.

Manufacturers tend to face certain challenges when implementing an industrial systems engineering solution, such as the complexity of integrating multiple systems, the need for specialized expertise, high upfront costs and the resistance to change existing workflows. Overcoming these challenges requires a well-planned and phased approach, strong support from leadership and effective change management strategies.

However, the transition period required to overcome these common challenges is worth the significant benefits of implementing an industrial systems simulation solution. Audi Hungary achieved added engineering value by switching from 2D to 3D models for manufacturing simulation, along with three main benefits: a surge in model value, faster project approval and acceptance and a significant performance boost.

Our industrial systems simulation solution is open and interoperable. Its modular portfolio includes the integration of Siemens automation equipment and facilitates co-simulation and communication with third-party systems (such as component behavior models, simulation tools or software-based management systems) through import/export capabilities and APIs.

Industrial systems simulation solutions enable analysis and validation of industrial system behavior with a high degree of fidelity. The solutions incorporate digital twin modeling by integrating physics-based models to create a virtual representation of the physical asset. This includes simulating dynamic behavior, interactions and performance characteristics of the physical system. Simulation software focuses on analyzing the behavior of the system based on the underlying physical principles. Siemens offers the most comprehensive digital twin, which — together with simulation — plays a crucial role in bridging the gap between the real and digital worlds.