Assembly & Production Flow

Within the business area Assembly & Production Flow’s we focus on assembly projects where we conduct and carry out various services including station design, design of assembly lines with associated standardized working methods, work instructions, balancing, time, materials, facade balancing, layouts, etc.

  • Product- and process preparation

    Preparation is the link between design and production. Designers develop products for function and the preparation examines the design to fit the product to a cost effective production.

    Preparation is the link between design and production. Designers develop products for function and the preparation examines the design to fit the product to a cost effective production.

    Virtual Manufacturing offers within the area Assembly & Production Flow consultants with long experience of preparation within all types of industries and systems. Our consultants have the experience of preparation systems such as Siemens TeamCenter (TC), Dassault Enovia, PTC Windchill and Monitor. Typical tasks we can help with are:

    • Preparation – DFA/DFM – Product examination.
    • Make or Buy analyses.
    • 3D preparation / Assembly DMU / Assembly simulation.
    • Process planning / Method preparation (Structure management).
    • System support such as ERP/PLM – Calculation times and standard times (MTM, SAM and AviX.)
    • Running curves/Pace – flow value – Value stream mapping (VSM) – Process mapping
    • DES Discrete Event Simulation – P-FMEA – Work instructions.
    • Station, line and material facade balancing.
    • Ergonomics, workplace design Cell / Line.
    • Investment calculations – Specifications – Technical procurement support.

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  • Work Instructions

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

    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.

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  • Layout

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

    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
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  • Discrete Event simulation

    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.

    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

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  • Logistics

    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.

    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

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  • System 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.

    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
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  • 3D Scanning

    With the help of 3D scanning you can get full access to your plant wherever you are in the world. You can even get a so called “virtual fly through”, both indoors and outdoors. The result of a 3D scan can be used to create a 3D layout for your plant regardless if it’s for a complete layout or for a single station. In addition it is faster to create a 3D layout with high precision compared to traditional measuring.

    Industrial 3D scanning and measuring

    We perform professional 3D laser scanning for technical surveying, virtual mapping and digitization of your buildings and production facilities. 3D scanning is a fast and efficient method for three-dimensional mapping of e.g. factories, production lines, workstations, installations and products. The 3D scan can be adapted to your CAD software.

    Benefits of using 3D scans:

    • 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. 

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