Assembly & Production Flow

Product- and process preparation is the bridge between design and production.

While designers focus on functionality and innovation, preparation ensures that products are ready for efficient, cost-effective, and scalable manufacturing. A well-prepared production process minimizes waste, reduces lead times, and enhances product quality.

At Virtual Manufacturing, we specialize in product- and process preparation within Assembly & Production Flow. Our consultants bring extensive experience across industries and systems, ensuring a seamless transition from concept to reality.

We work with leading preparation systems such as Siemens TeamCenter (TC), Dassault Enovia, PTC Windchill, and Monitor, helping companies optimize both product design and production processes for increased efficiency and sustainability.

How we support your preparation process:

• Product- and process preparation – DFA/DFM analysis, design review, and manufacturability assessments.
• Make or Buy analyses – Strategic decision-making to balance cost, quality, and supply chain resilience.
• 3D preparation – Assembly DMU, digital mock-ups, and virtual assembly simulations to optimize production before physical implementation.
• Process planning & method preparation – Structure management, process documentation, and workflow optimization.
• System support (ERP/PLM) – Calculation times, standard times (MTM, SAM, AviX), and digital integration for smooth operations.
• Production flow optimization – Running curves, takt time calculations, Value Stream Mapping (VSM), and process mapping.
• Simulation & risk analysis – DES (Discrete Event Simulation), P-FMEA, and the creation of clear work instructions.
• Balancing & workplace design – Station, line, and material facade balancing to maximize efficiency.
• Ergonomics & lean production – Optimization of workstations for safety, comfort, and productivity.
• Investment & procurement support – Cost calculations, technical specifications, and procurement guidance.

By leveraging our expertise in product- and process preparation, we help companies enhance production efficiency, reduce costs, and ensure high-quality output. A well-prepared manufacturing process lays the foundation for long-term success.

Let’s streamline your production – together!

Virtual Manufacturing have a long and broad experience in developing the best possible support for operators in the automotive, aircraft and traditional manufacturing industry.

According to “The Virtual Way” Virtual Manufacturing wants to, as early as possible, begin work on the work instructions. This in order to get feedback from both designers and operators in an early phase of development. We prefer to be involved in delivering a first draft of the work instruction already during the prototype production stage.

In our “Virtual Training” concept we have various tools/support that allows operators to test their knowledge in areas such as article number, assembly sequence, component knowledge, choice of tools and equipment and rules of procedure. We want to prepare  the operators and obtain their participation and feedback in an early phase. The final will be our gate “Virtual Start of Production – VSOP”. The goal in this stage is to lift focus to the entire workplace. We are well familiar with improving the work instruction and reaching the first stage of standardized work.

Virtual Manufacturing uses 3D and 2D layout as a tool for planning, simulation and communication in all types of development projects.

A 3D layout is simple to understand because it shows the height in the room, ports, overhead, ventilation pipes etc. Early during the design process it shows the challenges and requirements in the production chain. Virtual Manufacturing offers consultants with broad experience within layout work in 2D as well as 3D. We produce 3D layouts at the implementation of flow analysises and design of work stations with correct material facads. Our work method consists of four phases: 3D scanning, Modelling, Structuring and Communication. Several alternative layouts are produced as decision support and VR is used to visualize and improve solutions.

Typical tasks we can help with:

• 2D and 3D layout
• ASIS – TOBE scenario
• 3D modelling of factory area, facilities and equipment with different accuracy requirements
• 3D scanning to verify existing 2D/3D Layout

Virtual Manufacturing performs flow simulation over production and logistics plants to map out current production and test ideas, without having to disturb the ongoing system. Simulation models makes it so that you can avoid surprises and errors in an early stage and that gives support to analyse the material and information flow in the production. A flow simulation visualizes the system, which will shorten the lead time and ease decisions at investments in new productions, production equipment and readjustment in the production.

Virtual Manufacturing provides consultants with broad experience within flow simulation and we create models that can analyze capacity, bottlenecks, buffer levels, product mix, inventory and balancing. We verify our customers’ thoughts and expectations before investment and possible reconstruction. We do visual models so that all parties involved can get an understanding for how the future solution will look like.

Typical tasks we can help with:

• Model av the daily production to understand how systems work and what parameters affect what.
• Capacity calculations
• Concept models
• Bottleneck analysis
• Secure investment of new line or parts of it
• Verify new and changed PLC logic in advance – Virtual Commissioning

Production logistics improves material flows within a production facility. This in order to achieve a smoothed and leveled flow of goods. Production logistics includes a holistic approach to managing the associated cost of the piece, from start of manufacturing and to the point of assembly. Within the lean manufacturing perspective production/operations and logistics are more and more phasing the same challenges and are forced to approach issues in a similar matter.

Virtual Manufacturing offers consultants with broad experience in various logistics missions, from traditional inventory management to paced logistics processes.

According to “The Virtual Way”, we seek to visualize all logistic flows with Material Flow Simulation. We work with traditional production techniques to balance out the various tasks and logistic system that tact in a production facility.

Typical areas of expertise include:

• Flow – Flow Simulation – Production Simulation DES – Discrete Event Simulation
• Capacity Calculations – trains, trailers
• 3D Layout / IN / OUT zones , Warehouse / High storage
• Design of materials Front, Kit wagons
• Replenishment Models , Kanban principle , Blanked Parts , Stopping,
• Packaging boxes, shadow boards
• Analysis method, time setting
• Cardboard / Packaging choice Vs Pace
• Construction Balancing & pack Instructions

The requirement for multiple product variants within the same manufacturing facility sets high demands on the development and ongoing production processes. From the time a product is conceptually defined in engineering and design to work instructions and repair manuals everything can be integrated with a system support. Ongoing production processes can be more efficient with the right method and system support. Understanding of communication between man and machine is crucial for successful development of IT support.

Virtual Manufacturing offers consultants with broad experience to challenge and develop how people, processes and systems work together. We offer a wide range of integration and application development services to streamline a company’s IT infrastructure. We develop support systems for our customer’s product development projects and their production and logistics processes. Our goal is to ensure that everyone works in a consistent, structured and effective way. There should always be a proven approach that is intuitive and easy to absorb.

According to “The Virtual Way” we work with the situation we are phased. We work with our client’s systems and history and help them we understand that and utilize their investment in the best possible way.

Typical areas of expertise include:

• Method Development, Application Development
• Training of personnel, integration, methodology support
• Testing of new releases, benchmarking
• Process Mapping, selection of work processes and systems
• Business Development, implementation of a PLM solution
• System Architecture , system Integration PLM / ERP / MES etc. System testing
• PLM – Structure of product data for production
• PLM – Structure of the Process Library
• PLM – Structure Property / Layout

Industrial 3D scanning and measuring

Virtual Manufacturing has extensive experience in 3D scanning, helping industrial companies worldwide map their production facilities. With 3D scanning, you gain access to an exact digital copy of your factory, no matter where you are. The results can be used to update 2D and 3D layouts, from individual workstations to entire buildings.

Point Clouds and 360° Images as a Foundation

A 3D scan generates a detailed point cloud combined with 360° images. This data allows you to navigate your factory directly in a web browser, giving everyone in the organization the same level of insight. Using the point cloud, you can measure heights, identify doors, ventilation systems, machinery, and other equipment. It can also serve as a reliable basis for creating CAD models of existing facilities and equipment.

Benefits of 3D Scanning in Production

With 3D scanning, companies can plan new production lines, factories, and logistics facilities in a three-dimensional environment. This makes it easier to detect issues early and avoid costly surprises. The technology is also the most cost-efficient way to carry out production changes.

3D scanning is often the first step toward creating a Digital Twin, or our own Virtual Twin, which provides even greater opportunities to simulate, analyze, and optimize production environments.

Typical Tasks We Support With

• Visualize your factory, production line, workstation or similar.
• Reverse Engineering & CAD Comparison
• Make measurements directly in the three-dimensional layout from the office.
• Add new layout proposals to the scan and check that no conflicts arise.
• The three-dimensional layout can be divided into individual components, such as machinery, piping, storage system operators, etc. This makes it possible to simulate and visualize the reorganization of the existing production.
• Operator Training in virtual reality.
• Webshare – the opportunity to access the mapping from any computer.

The scanning equipment is not bulky and production can continue uninterrupted while the 3D scan is made. We can scan objects of all sizes, both indoors and outdoors.