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How to use simulations as part of your design process in building your factory automation system

Updated: Aug 19, 2022

Efficiency is the bedrock of success in the modern manufacturing landscape. Even then, achieving efficiency depends on the ability to eliminate errors and other production bottlenecks that may lead to inadequacies and losses. Modern factories rely on overly complex and often expensive to maintain manufacturing systems, which may be susceptible to errors, which lead to time and resource wastage.

With this in mind, factories now use simulation projects to address underlying gaps in a bid to maximize profits. Simulations are useful in the factory system automation process. Simulation is critical in identifying potential issues in the production process before they occur. Some typical potential problems include wastage of materials, product defects, or bottlenecks in the production line.

The actual cost-saving effects are evident when companies predetermine such issues through simulations. PrimeTest Automation focuses on customized automation solutions for all your production needs. By using simulation tools including Fanucs ROBOGUIDE, Solidworks, and 3D Printers for prototyping, PrimeTest Automation provides long-lasting factory automation systems.

In this article, we reflect on how to use simulations as part of your design process in building your factory automation system. This article will also assess some useful simulation tools in automated systems within a factory setting.

Digital Simulation as the Modern Driver of Efficiency in Production

Digital simulation is an investigation method that examines the actual phenomenon, processes, devices, and systems within a given content. The technique relies on the study of mathematical models by utilizing digital computers. Simulation uses technology in production to simulate every phase of the product manufacturing process and identify gaps that hinder productivity.

Factory automation systems exist to automate manufacturing processes to increase and enhance productivity. Simulation improves the automation of your factory's end-to-end manufacturing process by identifying and eliminating any bottlenecks in the production process.

Simulation enhances the factory automation system through the cost-effective testing of diverse product iterations. What's more, these improvements are possible without creating additional physical prototypes.

Benefits of Using Simulations to Improve Factory Automation Systems

The modern manufacturing context relies on factory automation systems to enhance production efficiency. With simulations, providing customized automation solutions is now more cost-effective. Simulation accords you the following benefits:

  • Reduced overall costs

  • Minimal time spent in the testing process

  • simulation reduces the convoluted process of operation to just a few minutes or less

  • The ability to test potentially dangerous systems without physical or financial risk is a huge plus

  • The possibility of testing and studying varying versions of a system is a major advantage

  • The ability to test different systems regardless of the environments is another critical benefit

  • One can control everything in the simulation process with incredible precision.

Simulation tools

Simulation tools help design and evaluate the options of designs before finalizing the product. Here're some of the best simulation tools:

  • FANUC ROBOGUIDE as a Tool for Simulation

The FANUC ROBOGUIDE is among the best simulation tools for factory automation systems. The robot stimulator stimulates the robot's motion and the application commands. With this tool, the production process saves significant time that would often be used in creating motion setups.

Once you save time in the new motion setups, the actual impact on the production process becomes minimal. Further, with this tool, it's possible to design, test, and modify cells with incredible ease offline.

The ROBOGUIDE simulation tool tops the list of the best offline programming software for factory automation. The tool helps users to create 3D simulation environments, which assists factories in designing and optimizing all processes and applications with unmatched efficiency.

The tools allow the users to transfer Simulation to robot controls in the production process. Such a complex transfer process is possible using ethernet connections. The application of this tool helps to cut down on machine downtime. Factories are also able to eliminate the constant risk of malfunctions.


SOLIDWORKS simulation is one of the easiest to use structural analysis tools. The tool uses Finite Element Analysis, which is helpful in the prediction of a product's real-world's physical behavior. The tool manages this prediction process through the virtual testing of CAD models.

Factories keen on automation can use SOLIDWORKS as a tool for Simulation. With this portfolio, your production process benefits from linear, non-linear static, and dynamic analysis capabilities.

The tool offers the following benefits:

  • Finite Element Analysis (FEA)-based structural analysis solutions incorporated in CAD to forecast real-world performance

  • Simple to use, extensive capabilities solve everything from a simple linear analysis of a single component to full simulations of complete assemblies with contact and non-linearities.

  • SIMULIA Abaqus technology is robust, proven, and scalable, and cloud-enabled solutions provide access to it.

  • Understanding the product's performance early in the design phase allows you to innovate more while avoiding rework.

  • 3D Printers for Prototyping

The process of creating a prototype is expensive and often slow. However, with the introduction of tools such as 3D printers for prototyping, it's now easy to develop prototypes in the production process.

The technology provides access to a wide range of efficient 3D printing solutions. Factories can now save significant time and money in production or manufacturing. You can also create various iterations. Regardless of whether you are dealing with simple or complex iterations, 3D printers for prototypes provide the best solutions compared to any other manufacturing technique.

Take Control of Your Factory Automation System Today

Automation is the backbone of any successful production line today. If you want to take control of the entire process from design to production, then simulations are the catalyst that will complete your factory automation system. Even then, you need reliable automation engineers to advise and take the lead in providing tested and tried solutions.

At PrimeTest automation, we have a mix of experience and professionalism within our team. We provide automated solutions for your factory using the most advanced simulation techniques. Some of our unique simulation tools that have proved useful in the process of designing and developing systems include Fanucs ROBOGUIDE, Solidworks, and 3D Printers for prototyping. With these tools, you can now use simulations as part of your design process in building your factory automation system.

You can contact us today for more information on our automation solutions and a model that suits your company's needs.

6681 NW 17th Avenue Ft Lauderdale, FL 33309

Toll-Free: 877-522-8439

Main: 561-912-9433



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