Project background
Operators wanted to model proposed line changes — new equipment, revised layouts, different shift patterns — before committing capital. The client needed a digital twin tied to live production data.
Challenge
Building models accurate enough to trust without becoming a full-time maintenance burden, and making the twin approachable to engineers who aren't simulation specialists.
Approach & solution
We built a discrete-event model anchored to live telemetry, continuously calibrated against actual throughput. A 3D view and scenario tooling allow what-if analyses without rebuilding the model. Configuration lives in version control for reproducibility.
Results & benefits
Several planned changes were validated or rejected through the twin before any capital commitment, saving cost on at least one project that looked good on paper but would have bottlenecked upstream.
