How to successfully enter the world of digital planning
For many companies, introducing simulation into production or logistics is a strategic step towards greater transparency, security and optimisation potential. But especially at the beginning, many fundamental questions arise. In this article, we answer eight common questions that we are asked particularly often by newcomers – in a concise, practical and understandable way.
1. How long does a simulation project take?
The duration of the project depends largely on its scope, objectives and the available data. Roughly speaking, there are three types of projects:
- Simple projects: e.g. layout evaluation of a sub-area, 2–4 weeks
- Medium-sized projects: e.g. throughput optimisation with variant comparison, 1–2 months
- Complex projects: e.g. comprehensive factory planning or digital twin, 2–6 months or more
Tip: A clearly defined question significantly speeds up the project process.
2. Do I need prior knowledge of simulation?
No – you do not need any special knowledge of simulation or modelling to work with SimPlan.
What you need to bring with you:
- Process knowledge and objectives
- Data, drawings or ERP extracts
- Questions you would like to clarify
We take care of:
- Model development
- Validation and analysis
- Preparation of results for decision-making
If you would like to do your own modelling later, you can take part in our practical training courses, e.g. for Plant Simulation, AnyLogic or Simio.
3. What data is required?
For modelling and subsequent evaluation, we generally require the following information:
- Layout data (e.g. DWG, PDF or Excel with process steps)
- Process times (processing, transport, buffer times, etc.)
- Quantity and throughput data (e.g. order volume, number of units)
- Resource data (e.g. personnel, machines, capacities)
A real-time connection is not necessary in most cases – however, it is important that the data is consistent and traceable.
4. How much does a simulation project cost?
The costs vary greatly depending on the complexity, objectives and data available. As a guide:
- Small projects: from approx. £5,000–15,000
- Medium-sized projects: £15,000–40,000
- Large projects: from £40,000 upwards
These ranges already include consulting, modelling, testing and presentation of results.
Note: A well-prepared project with clear objectives and good data is usually more cost-effective.
5. What software is used?
We work independently of manufacturers and select the tool that best suits your requirements. Typical simulation tools are:
- Plant Simulation – for material flow and production
- AnyLogic – for agent-based, dynamic or hybrid models
- Simio – for flexible, object-oriented models and virtual commissioning
- Emulate3D – ideal for virtual commissioning in automation
- You can find more tools here in the software overview
The software is selected on an individual basis – depending on the objective, data formats, model requirements and any existing infrastructure.
6. How does a simulation project typically proceed?
A simulation project usually proceeds in the following steps:
- Definition of objectives: What needs to be investigated, compared or verified?
- Data review: What information is already available? What needs to be added?
- Model development: Creation of a digital representation (using software of your choice)
- Validation: Comparison with actual data or expert knowledge
- Evaluation & presentation: Results, recommendations for action, comparison of variants if necessary
We work iteratively, transparently and in close coordination with your project team.
7. Can we reuse the model ourselves later?
Yes – on request, we can create the model so that it can be used by you on a long-term basis. This includes:
- Model handover with usage rights
- Documentation and structuring
- Training of future users
Many companies subsequently use the model for:
- Training new employees
- Recurring analyses in the event of order changes
- Long-term planning scenarios (‘What if…’)
8. When is simulation worthwhile?
Simulation is particularly worthwhile when:
- Processes are complex or varied
- Investments need to be secured
- Bottlenecks are suspected but not proven
- Several possible solutions are available
- Changes need to be tested without risk
Typical areas of application:
- Production planning
- Layout evaluation
- Material flow simulation
- VIBN (virtual commissioning)
- Warehouse and transport logistics
Summary
Simulation is a powerful tool that makes complex processes visible and supports important decisions – without any risks to ongoing operations.
For beginners: don’t be afraid – with the right support, getting started is clear, understandable and economically sensible.
