From experience-based design to simulation-driven certainty

How System 3R uses simulation to engineer the next generation of automation

For many years, System 3R designed its automation systems based on deep engineering experience and well-founded assumptions. This approach proved effective for relatively simple manufacturing cells, where system behavior could be estimated with sufficient confidence. However, the landscape of industrial automation has changed fundamentally.

Rising complexity demands a new approach

Automation solutions today are no longer isolated cells. They have evolved into large, highly integrated production systems that combine multiple technologies—cleaning machines, measuring systems for quality assurance, machining centers, robots, and increasingly, autonomous mobile robots (AMRs) for intralogistics.

As these systems grow in scale and complexity, traditional estimation methods reach their limits. Questions such as robot utilization, system throughput, buffer sizing, or operator workload can no longer be answered reliably without a quantitative, model-based approach.

This is especially true when considering System 3R’s vision of a future “lights-out factory,” where multiple automation solutions operate autonomously and are interconnected via AMRs. In such environments, simulation is not optional—it is essential.

Choosing simulation as a strategic capability

Recognizing these challenges, System 3R decided in 2023 to actively seek a trustworthy partner in the field of simulation. The goal was clear: to complement engineering expertise with robust, data-driven decision support. This search led to a partnership with Systems Navigator.

While not every plant is simulated today, experience shows a clear pattern: wherever simulation is applied upfront, System 3R is able to design systems that are precisely aligned with customer specifications and operational targets.

Better decisions through virtual experiments

Simulation enables System 3R to analyze and evaluate the impact of changes long before a single machine is installed. By running multiple experiments and scenarios, engineers can assess different layouts, machine configurations, and operating strategies.

This makes it possible to:

• Identify bottlenecks early—whether at robots, machines, buffers, or magazines

• Quantify the effects of parameter changes

• Provide customers with well-founded recommendations instead of assumptions

Real-world results from simulation projects

In one project in Japan, simulation was used to determine the required storage capacity to support 24/7 production. The analysis ensured that machines would always have sufficient material available, directly contributing to faster system amortization.

The same model was used to evaluate operator workload and the effects of optimized processing times. The results were revealing:

• A 40% reduction in processing times did not create new bottlenecks

• Reducing the number of operators to two did not decrease system output

These insights allowed the customer to make informed decisions based on facts rather than expectations.

In another customer case, simulation focused on system sizing. The customer initially planned for six machining centers and three measuring machines to achieve the desired output. Simulation showed that four machining centers and two measuring machines were not only sufficient, but capable of significantly exceeding the production target.

The outcome: substantial savings in machine investment, personnel requirements, and clamping capacity—without compromising performance.

Simulation is only as good as the data behind it

As powerful as simulation is, its accuracy depends entirely on the quality of the underlying data. Clear definitions of processes, processing times, control logic, and boundary conditions are essential.

Establishing this foundation requires significant upfront effort—from System 3R, from Systems Navigator, and from the customer. But this effort pays off by reducing risk, avoiding over-engineering, and enabling confident investment decisions.

Conclusion

As automation systems become larger, more integrated, and more autonomous, experience alone is no longer enough. Simulation bridges the gap between engineering intuition and operational certainty.

For System 3R, simulation has become a key enabler for designing efficient, future-ready automation solutions—and a decisive factor in delivering measurable value to customers.

Curious how simulation modeling can support your automation project? Contact us to find out.