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Siemens Tecnomatix Process Simulate

Process Simulate is a virtual commissioning simulation tool that allows you to verify robot processes and automated lines in a virtual space and connect the results to actual equipment.

By faithfully reproducing the robot's motion precision, range of motion, and speed, the feasibility of the entire process, involving humans, robots, and equipment, can be recreated in a virtual space, allowing for pre-implementation verification (digital twin).

It's possible to visualize "interference," "safety," "cycle time," and "startup risk"—factors that were invisible with Excel or empirical rules—through movement and numerical data, allowing for decision-making during the design phase.

This prevents the "rework" that was previously done on-site after the product was made, resulting in zero rework.

Manage multiple robots and peripheral equipment in a single digital environment.

Even in complex processes, interference and optimal operation can be confirmed.

Do you have a problem like this?

Downtime cost issues
Each time the production line is stopped, a significant amount of downtime occurs.
The problem could not be resolved through robot adjustments, resulting in rework in robot selection and line design.
Judgment and quality issues
The judgment of validity is subjective and lacks reproducibility and transparency.
The basis for the improvement measures is not data, but rather intuition.

While the downtime is becoming longer, the validity of the improvement results remains unclear.
As a result, a situation arises where "it's difficult to change once a decision has been made," and the PDCA cycle doesn't function properly in the workplace, doesn't it?

for example…

  • Since introducing the robotic process, adjustments and modifications have been required on-site.
  • Interference between multiple robots and surrounding equipment can only be observed with the actual machine.
  • There is room to shorten cycle times, but it's unclear where improvements should be made.
  • Creating and modifying robot programs is taking a lot of time.
  • Understanding the scope of impact when design changes are made is time-consuming.

 

Process Simulate addresses these challenges specific to robotic processes at the design stage.

What you can do with Process Simulate

Faithfully reproduces realistic robot movements.
You can verify the robot's movements in advance under conditions equivalent to those of the actual machine.
The robot's motion accuracy, range of motion, and speed are accurately simulated.
Automate collision detection and safety area checks.
We provide standard OLP drivers compatible with many robot manufacturers.
We provide prompt support for new models and new manufacturers.
Integrated simulation of the entire multi-axis robot line
This allows you to verify whether the entire production line is functioning correctly, not just the robots individually.
Manage multiple robots and peripheral equipment in a single digital environment.
Check for interference between robots and equipment all at once.
We consider the optimal actions and arrangements while taking an overview of the entire process.
Automatic program generation and performance optimization
The results of the analysis will be converted into data that can be used directly on the actual device.
Automatically generate highly reproducible robot motion programs from simulation results.
Optimize paths and speeds to reduce cycle times.
Reduce manual program modifications
Risk reduction and cost reduction before implementation
We eliminate "unforeseen" issues during the initial setup phase.
Detection of interference with existing equipment and conveying equipment before installation.
Pre-verification of coordinated operation with conveying equipment
Applying optimal simulation results to the actual machine accelerates startup.
Speeding up the PDCA cycle and improving the reproducibility of designs.
Improvement planning can be conducted in a virtual space rather than on-site.
Compare and verify multiple options in a short amount of time.
Reduce actual device downtime
Visualize the evaluation process and improve the transparency of decision-making.
Integration with PLM (Teamcenter)
Process design data is managed centrally without being fragmented.
CAD/BOM/BOP/Simulation history management
Version control of OLP data
Verification of control logic (virtual PLC/RCS)
Automatically extract the scope of impact when design changes are made.

Case Study

Case Study A: Resolving rework in the manufacturing process

Task
Frequent rework and schedule delays in the manufacturing process.
The risk of unexpected software bugs slowing down the process.
Implementation details
We conduct simulation verification and optimization for complex use cases and failure modes in the early stages of the project lifecycle.
Introduction result
The time from design to on-site commissioning has been shortened from the conventional 6-8 months to 3 months.
By reducing rework through early verification, the project duration was significantly shortened.
Development speed and launch reliability have improved.

Case Study B: Reducing trial run and implementation time

Task
Increased cycle length and virtual debugging time required for on-site commissioning.
High costs associated with quality assurance.
The burden of introducing manufacturing equipment to meet each customer's custom requirements.
Implementation details
Pre-verification was conducted using simulations covering the entire production line, and much of the debugging was completed in a virtual environment.
Introduction result
Simulation accuracy: up to 98%
Actual device debugging time: 35% reduction
Project cycle: Reduced by up to 30%​
High-precision simulations enable verification that is nearly identical to reality, reducing on-site rework and quality costs.
This reduces the burden of introducing customized equipment, resulting in shorter delivery times and cost efficiency.

Case Study C: Achieving high-quality startup at low cost

Task
Increased time and cost due to large-scale debugging and installation/wiring work resulting from the waterfall process.
Prototyping and managing multiple prototype assets is costly and presents challenges in terms of availability.
Implementation details
Enhanced preparation through parallelization of engineering tasks and execution of back-office operations in a virtual environment.
Introduction result
Line readiness before actual operation: 90% reached
Field debugging time: Reduced by 40%​
Total cost: 10% reduction
Parallel verification in the back office reduces the workload on the field, avoiding rework and lengthy debugging sessions.
Reducing reliance on prototypes lowers asset costs and procurement risks.

Please contact us first for a consultation.

At Macnica, we offer individual consultations regarding the implementation and utilization of Process Simulate, and we propose approaches tailored to each customer's specific situation.

Please feel free to contact us for a consultation.

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