Line Optimization Services

Line Optimization Services is powered by Brunel

Brunel supports customers in their digital transformation by delivering integrated solutions that connect IT security, smart & industrial engineering, and quality management. Through our Solutions Hub, we enable secure infrastructures, digital factory planning, process automation, and lean operations. This empowers clients to increase efficiency, reduce risks, and accelerate innovation - ensuring a future-ready, competitive, and sustainable digital evolution.

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Why let commissioning reveal what simulation can prevent?

Manufacturing investment decisions rarely come with a second chance. For plant engineers and managers across production environments, the gap between planned and actual performance at commissioning can be costly. Brunel's Line Optimization Services is an expert-delivered engineering service. Dedicated simulation specialists test, validate, and refine production designs and workflows virtually using digital twin technology before implementation.

Robotic arms handling boxes on assembly line

Benefits

Identify layout weaknesses and control strategy gaps before physical implementation begins. Virtual testing reduces the financial impact of late-stage corrections, cutting the cost and disruption of changes that would otherwise surface during commissioning.
Improve production line throughput and maintain process stability through scenario-based simulation. Test scheduling changes, equipment configurations, and routing decisions virtually to find the most productive setup without interrupting live operations.
Pinpoint capacity constraints and throughput bottlenecks across the production line using simulation-derived data. Targeted improvements are validated virtually before implementation, removing guesswork from resource allocation and production planning.
Model energy consumption at machine and process level to detect waste and inefficiencies across the line. Simulated alternatives allow teams to test and select more sustainable configurations before committing to physical changes or capital investment.
Virtual validation significantly accelerates the planning phase, producing higher-quality decisions with fewer iterations. Deviations are identified and corrected in the simulation model, reducing ramp-up time and the effort required at commissioning.

Featured Capabilities

Lego-like blocks with manufacturing icons

Virtual production line modeling

Build accurate digital twins of machinery, staff, and logistics flows to replicate real production conditions. Support layout testing, capacity analysis, and validated planning decisions across the full production environment before any physical change is made.

Factory simulation with blocks and robotic arm

What-if scenario simulation

Test layout changes, routing options, geometry configurations, robotics simulation, and kinematic modelling across multiple production scenarios. Results are evaluated against defined KPIs to identify the optimal production configuration before investment decisions are finalized.

Robotic arms on assembly line with data chart

Energy consumption analysis

Simulate energy consumption at machine and process level to pinpoint inefficiencies across the production line. Test alternative configurations virtually to reduce operational costs, cut emissions, and build a measurable case for more sustainable production.

Ramp-up time optimization

Simulate and validate new production lines across brownfield and greenfield environments before physical setup begins. Reduce commissioning deviations, shorten ramp-up timelines, and reach stable production faster with lower startup risk and more reliable planning outcomes.

Siemens tool integration

Apply Tecnomatix Plant Simulation with Software-in-the-Loop (SiL) and Model-in-the-Loop (MiL) methodologies to validate control strategies, cycle times, and fault scenarios virtually. Full-scale optimization across design, control, and operational phases from one integrated workflow.

Real World Applications

Optimizing high-speed packaging lines

Simulate and optimize food packaging lines to reduce bottlenecks, with indicative improvements of up to 5–15% shorter changeover times, 5–10% higher throughput, and 5–15% lower energy consumption. Virtual testing supports hygienic and efficient layout planning without disrupting ongoing operations.

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Additional Information and Resources

Brunel Solutions Hub Industrial Engineering & IT