Using simulation-based Digital Twins to optimize shipyard design and production

The shipbuilding industry is under increasing pressure to reduce construction time, control costs, and improve operational efficiency—while managing ever-growing complexity in production and logistics. Simulation-based digital twins are emerging as a powerful tool to meet these challenges by enabling data-driven design and decision-making before physical investments are made.

Virtual shipyard layout

A recent project demonstrates how digital twin technology can be effectively applied to shipyard development and optimization. The work was carried out by a student from Zeeland University of Applied Sciences, with professional support from industry and simulation experts.

From academic research to industrial application

The project was supported by Systems Navigator, and supervised by a shipbuilder. Together, they bridged academic research and real-world industrial application by developing a virtual model of shipyard production and logistics processes.

Using Simio simulation software, a detailed digital twin was created to represent employee movements, material flows, and workstation interactions within a shipyard environment. Rather than relying on static layouts or assumptions, the model allowed the team to simulate dynamic behavior across the entire production system.

Case study: Designing a new shipyard in Vlissingen

The model was applied to a real case study focused on the design & optimizing of a new shipyard in Vlissingen. This provided a realistic and complex environment in which to test the model’s capabilities.

Facility layout in Simio

By simulating the production and logistics processes, the simulation model enabled accurate analysis and optimization of employee paths and material flows. Various scenarios could be tested digitally using real-time data, making bottlenecks immediately visible. This insight allowed workstations to be positioned more efficiently and logistics routes to be optimized before construction began.

Benefits of simulation-driven digital twins

The results highlight several key advantages of using simulation-based digital twins in shipbuilding:

• Improved visibility into production constraints and logistics inefficiencies

• Faster innovation cycles by testing alternatives digitally rather than physically

• Reduced risk and cost as design errors are identified early

• Optimized construction time and costs for complex naval vessels

By validating design choices in a virtual environment, shipyards can make informed decisions with greater confidence and avoid costly late-stage changes.

A proven approach for future shipyard development

This project illustrates how simulation digital twins are no longer theoretical concepts but practical tools with immediate value for the shipbuilding industry. The collaboration between academia, simulation specialists, and a leading shipbuilder demonstrates how digital transformation can be effectively implemented in industrial practice.

As shipyards continue to modernize, simulation-driven digital twins will play an increasingly central role in designing efficient, resilient, and future-proof production systems.

Curious how simulation can support the design of new shipyards? Contact us to find out.