Simulation Smart Factories: a smart idea

A Smart Factory is a complex set of production machinery, logistics and handling. To see how designs turn out in practice, ViManPro offers advanced 3D simulation software that accurately mimics processes. Upon request, ViManPro makes simulations for companies that not only support the designer, but also the sales department.

The management of ViManPro has 30 years of experience in special machine building and is familiar with production processes, robotics and automated systems. Several years ago, a search was started for suitable 3D simulation software to pre-simulate these machines in a specific environment. Jan Peelaerts, Managing Director at ViManPro: "By simulating processes, hardware and software, you can see intended solutions in a virtual world. How do processes run, where are the bottlenecks, what is the impact of certain changes?"

Choose one

After a search in which several suppliers were invited, the choice fell on the Finnish manufacturer Visual Components. To cut a long story short, support in Belgium was minimal, making it difficult to get questions answered. Peelaerts: "In Germany, the software was represented by Dualis; a company that works with it itself, which means it is the optimal partner for German users. Furthermore, it develops practical add-ons for this software as well as component libraries and is uniquely capable of translating customer-specific questions into the program. Eventually, a partnership was formed between Visual Components, Dualis and our new company called ViManPro, which stands for: Visualizing Your Manufacturing Processes."

The software

Visual Components can be used at various levels. First, a fairly simple start is made with building the layout virtually, based on components from a library containing around 3,000 components. About half of these consist of robots from a variety of manufacturers. Then the processes are simulated where the user can go as deep as he wants. He can make his robots work, AGVs drive, people walk and so on. Once the model has been built, the real simulation phase follows in which changes can be made to the design at will, to see if processes can run better, more efficiently but also safer, for example. Peelaerts: "By means of simulation, you can detect and solve possible bottlenecks before you start building something. Furthermore, you can vary endlessly with different systems from different suppliers because you can choose any brand you want from the library. This means you are not directly tied to a manufacturer but can design your own ideas at your leisure. In addition, the model can be coupled with external software; for example, a Siemens PLC controller or a virtual robot controller. Through this linkage, the machine can be 'virtually' put into operation. Ultimately, the simulations lead to (much) lower failure costs when building new production lines in Smart Factories and the start-up phase can be carried out faster."

Together with the customer

But the software offers more advantages. The model is not redundant after the line is built, but can be used continuously for optimizations and trying out new ideas. Peelaerts: "Last but not least, it is an optimal tool for showing your own customers what you offer as a machine builder. You can write everything down so well, but when the customer sees the line working in his own environment - via a film, a 3D pdf or a rendered film - he can immediately see it for real. It also gives him the opportunity to participate in the design process, which reduces the chance of 'forgotten' details."

To make it as easy as possible for its own customers, ViManPro builds the simulations in-house. But purchases and training in the use of the software so that customers can use it themselves is also possible.