Factory Simulation

Considering an investment in a new production line, or even a whole new factory? Before you commit, we build your production virtually and run it: capacity, flow and bottlenecks become visible before a single machine is bought.

With scenario-based analysis, you decide on the layout and process design on simulation data, not estimates. What a simulation really produces is not an animation but decision intelligence: every alternative’s capacity, cycle time and bottleneck side by side as numbers, so which option is better, and why, stops being a matter of opinion.

The Questions It Answers

• Will this line make the target quantity, and which station is the bottleneck?
• How many months does one more machine or one more operator take to pay back?
• Which layout makes more: manual, with cobots, or with AGVs?
• How does the line behave when the product mix changes, and where do buffers build up?
• How does a new factory’s layout change material flow and walking distance?

Two Tools

• ONO SIM: the line simulator we build ourselves. It runs the line through a real shift; the optimiser finds the cheapest way to the target and lists each suggestion with its payback. Runs in the browser.
• Visual Components: for detailed 3D engineering studies. With more than 3,500 ready components and more than 1,600 robot models, robot cells, conveyors and internal logistics are modelled at true scale. The same model is used for virtual commissioning and offline robot programming.

How a Simulation Project Runs

1. The question is set. Which line, which decision, which constraint.
2. We gather the data together. Layout drawing, cycle times, product mix, shift pattern. We start with whatever you have; gaps are measured together on site.
3. The model is built. If the line exists, the model first matches today’s output; scenarios run after that.
4. Scenarios are compared. Breakdowns, scrap, operator walking and buffers are part of the model.
5. The result is delivered in numbers. Bottleneck, capacity, cost per part and payback period, with a comparison table and our recommendation.

We wrote up an example study on the blog: four builds of the same line, from 53 parts an hour to 161.

Shall We Run It, or Will You?

• We run it: under engineering consultancy, we model your line and run the scenarios; you don’t need to learn any software.
• You run it: if you want to keep simulation in-house, we supply the Visual Components licence as the authorised distributor for Turkey and the Middle East, with training and onboarding support in Turkish.

Simulation or Digital Twin?

Simulation answers questions before the line is built; a digital twin follows the line with live data once it runs. We explain when each one helps in this article.

Who It’s For

Manufacturers building a new line, expanding an existing one, or planning a factory from scratch; anyone who wants to make the investment decision on simulation data rather than guesswork.

Frequently Asked Questions

What is factory simulation?

A model of a production line or a factory, with its machines, operators, material flow and rules, that runs on a computer. The model is run like a real shift, so capacity, bottlenecks and buffers show before anything is tried on the floor.

What data does a simulation need?

A layout drawing, cycle times, the product mix and the shift pattern are enough to start. We start with whatever you have; missing values are measured together on site.

Can our own team run factory simulations?

Yes. Ono Teknoloji, the authorised Visual Components distributor for Turkey and the Middle East, supplies the licence with training and onboarding support in Turkish. Ono Teknoloji can also run the whole project for you.

What is the difference between simulation and a digital twin?

Simulation answers what-if questions before a line is built. A digital twin follows a running line with live data from its machines. Ono Teknoloji does both: ONO SIM and Visual Components for simulation, OnoTwin Studio for the digital twin.