Manufacturing Software & Services

Virtual Twin gives Digital Insight for Optimized Production

A Virtual Twin gives digital insight into your factory, capturing real conditions through 3D scanning and interactive visualizations. This enables teams to identify hidden obstacles, simulate layout changes, and optimize workflows before making physical changes, reducing risks and improving operational efficiency.

Production Challenges Solved by a Virtual Twin

Many factories face hidden obstacles that cause inefficiencies, delays, and errors. A Virtual Twin helps you overcome these challenges by providing a complete, interactive digital representation of your facility:

• Hidden problem areas: Identify inefficiencies before they become costly. Engineering & Planning benefit from faster project execution, better space utilization, and fewer errors.
• Space limitations, height restrictions, and equipment conflicts: Visualize constraints and plan layout changes accurately. Production teams gain optimized workflows, real-time KPIs, and digital work instructions.
• Outdated or incomplete data: Avoid mistakes caused by old drawings or missing information. Maintenance & Facility Management can navigate systems and instructions with ease.
• Flow inefficiencies and new installations: Simulate process flows and changes digitally before implementation. Health & Safety teams can conduct virtual safety training and visualize risk areas.
• Siloed information across departments: Improve collaboration and understanding across the organization. Marketing, HR & IT can conduct virtual factory tours, workshops, and team training.

Interactive Points of Interest (PoI): Add layers of information directly to objects and areas within your Virtual Twin. PoIs can include work instructions, safety notices, inventory lists, Kaizen initiatives, or links to other systems. This turns your digital model into an actionable workspace, enabling teams to make data-driven decisions faster and more accurately.

By addressing these challenges with a Virtual Twin, you reduce project risk, accelerate planning, and unlock measurable improvements across your entire organization.

From 3D Scan to Virtual Twin

A 3D scan produces a point cloud that forms the foundation of your Virtual Twin. The data can be used to:

• Build an accurate 3D model of the facility
• Measure objects and distances with millimeter precision
• Plan layout changes and test TO-BE scenarios
• Create a digital basis for decision-making, simulation, and optimization

With a Virtual Twin, you can move objects, test changes, and optimize processes digitally before implementation – saving time, reducing costs, and increasing safety.

Value and Results

A Virtual Twin gives Digital Insight to your factory and enables:

• Data-driven production and layout optimization
• Efficient collaboration and communication
• Faster implementation of changes
• Long-term digital factory development

Would you like to know more contact Daniel Wigren for Europe, Richard Gould for UK and Irland, Pontus Rosengren for rest of the world

Tulip for Frontline Operations

Tulip for Frontline Operations digitizes production workflows, connects machines and systems, and empowers operators with real-time data. By replacing paper-based processes and disconnected tools with scalable, cloud-based applications, Tulip improves quality, traceability, and productivity across the production floor. Instead of reacting to deviations after they occur, teams gain live operational visibility, enabling faster decisions, fewer errors, and measurable performance improvements.

Eliminate Waste and Improve Performance

Manufacturers often struggle with:

• Process variability and inconsistent work methods
• Manual data entry and paper-based documentation
• Limited visibility into bottlenecks and downtime
• Slow deviation handling and quality reviews
• Siloed information across departments

Tulip for Frontline Operations standardizes work through guided digital instructions, automated data capture, and live dashboards. Operators follow structured workflows, deviations are identified instantly, and performance data becomes transparent.

The result is reduced rework, shorter lead times, improved OEE, and stronger production stability.

Built for Lean Manufacturing Across Industries

Tulip delivers value across different production environments:

Discrete Manufacturing

• Standardize assembly processes
• Improve operator performance and reduce rework
• Gain real-time insight into production KPIs and bottlenecks

Pharmaceutical Manufacturing

• Enforce SOP compliance and electronic signatures
• Accelerate batch release with review-by-exception
• Ensure data integrity and audit readiness

Medical Device Manufacturing

• Reduce training time with guided workflows
• Strengthen traceability across production
• Support validation and new product introduction

Regardless of industry, Tulip creates an environment that supports Lean principles, transparent, and continuously improving production.

Software-Driven Governance and Scalable Digitalization

Tulip is more than workflow digitization, it is an enterprise-ready software platform designed for governance and scalability.

With built-in access control, version management, approval workflows, and system integration capabilities, companies can:

• Control user roles and secure sensitive production data
• Standardize app development across sites
• Deploy templates and best practices globally
• Integrate with ERP, MES, and machine systems
• Scale digital solutions from pilot to enterprise level

This ensures that digital transformation is not only fast, but also controlled, compliant, and sustainable.

Measurable ROI from Day One

By implementing Tulip, manufacturers achieve:

• Higher product quality and fewer deviations
• Faster release cycles and improved traceability
• Increased productivity and reduced downtime
• Better cross-functional collaboration
• A scalable foundation for long-term digital transformation

Tulip transforms frontline work into a connected, data-driven ecosystem that delivers operational excellence.

Would you like to know more contact Daniel Wigren for Europe, Richard Gould for UK and Irland, Pontus Rosengren for rest of the world

Tulip

Real-Time Asset Tracking for Manufacturing

Gazpacho Tracking Real-Time Asset Tracking provides real-time visibility of assets across your production and logistics operations. Misplaced equipment, delayed materials, and inefficient workflows can slow production, increase costs, and frustrate customers. Gazpacho Tracking ensures operators always know where key assets are, reducing downtime, boosting efficiency, and improving overall operational performance.

By combining Real-Time Asset Tracking with ERP integration, you gain actionable insights that help you streamline processes, optimize material flow, and make informed decisions before small issues turn into major disruptions.

Production Challenges Solved by Gazpacho Tracking

Factories often face hidden operational hurdles:

• Delays in material flow and misplaced tools or components
• Inefficient internal logistics causing slower production cycles
• Limited visibility into assets and equipment utilization
• Safety risks from uncontrolled equipment or vehicle movements
• Errors caused by outdated floor plans or siloed information

Gazpacho Tracking solves these challenges by delivering continuous location data. Operators can quickly locate components, forklifts, or tools in real-time, simulate workflows, and avoid costly errors, improving efficiency and predictability across the facility.

Key Benefits Across the Organization

• Engineering & Planning: Faster project execution, better space utilization, fewer errors
• Production: Real-time KPIs, improved workflows, and digital work instructions
• Maintenance & Facility: Easy access to system and equipment information
• Health & Safety: Visualize risk areas and ensure compliance
• Operations & IT: Monitor assets, generate analytics, and support Lean initiatives

Gazpacho also allows Point of Interest (PoI) tagging, enabling operators to link equipment, work instructions, or safety information directly to assets for immediate context and guidance.

Choosing the Right RTLS Technology

The architecture of your asset tracking system is tailored to your specific needs and environment. Each technology, Wi-Fi, RFID, BLE, VSLAM, GPS, UWB, or LoRaWAN has strengths suited to different use cases.

We evaluate factors such as required accuracy, asset type, indoor vs. outdoor environment, battery life, and integration with existing systems to recommend the optimal solution. Whether you need continuous real-time tracking of materials, location-based alerts, or historical data for process improvement, we design a system that ensures reliable performance, scalability, and measurable impact on efficiency and productivity.

Case Study: Material Tracking at Sulzer Pumps

Background: Sulzer Pumps manufactures engineered-to-order pump packages for the energy industry. Handling numerous unique components across the shop floor posed operational challenges and long lead times. Sulzer needed a real-time solution to track components and equipment efficiently.

Approach & Solution: Virtual Manufacturing, developed Gazpacho Tracking using BLE hardware and advanced location algorithms. The system integrates ERP data with real-time location data, allowing operators to pinpoint items instantly (e.g., “Where is the shaft for Project Y?”).

Outcome & Advantage:

• Accurate real-time location of components and forklifts
• Reduced operational delays and material search time
• Expanded implementation to three additional factories
• Enabled digital Andon system for rapid operator support
• Foundation for analytics to generate spaghetti diagrams and improve material flow

Next Steps: Virtual Manufacturing is exploring advanced analytics and ERP integration to unlock even greater insights and continuous improvement.

Testimonial:
“We selected Virtual Manufacturing to deliver our material tracking solution due to their understanding of our needs and collaborative approach. From Day 1 after commissioning, we achieved our objectives and are now exploring additional areas to extract insights from the data.” – Andrew Anderson, Sulzer Pumps

Read full Case Study

Why Choose Gazpacho Tracking?

With Gazpacho Tracking, manufacturing organizations can:

• Reduce downtime and production interruptions
• Optimize material flow and asset utilization
• Improve operator efficiency and workplace safety
• Support Lean initiatives with actionable, fact-based data
• Make data-driven decisions in real-time

From live monitoring to historical analytics, Gazpacho Tracking transforms asset visibility into operational performance and measurable ROI.

Would you like to know more contact Daniel Wigren for Europe, Richard Gould for UK and Irland, Pontus Rosengren for rest of the world

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Operator Movement Analysis in Manufacturing

Gazpacho Analytics transforms operator movement data into actionable insights that improve production flow, reduce waste, and increase operational efficiency. With Operator Movement Analysis in Manufacturing, you gain a clear, data-driven understanding of how operators, materials, and equipment move through your facility.

Instead of relying on assumptions, Gazpacho Analytics provides measurable data that enables faster decisions, validated improvements, and stronger production performance.

Turn Operator Movement into Measurable Performance

Lack of visibility into operator movement often leads to hidden inefficiencies. Gazpacho Analytics makes these patterns visible by converting tracking data into:

• Spaghetti diagrams showing actual operator paths
• Heatmaps highlighting congestion and inefficient work areas
• Zone-based insights using geofencing

This allows you to identify unnecessary motion, waiting time, and deviations from standard work.

Identify Inefficiencies and Optimize Flow

Gazpacho Analytics enables you to:

• Analyse operator movement vs. idle time
• Measure distance travelled and route efficiency
• Detect congestion and risk of collisions
• Compare actual movement with defined standard paths
• Evaluate takt time and process adherence

With Operator Movement Analysis in Manufacturing, improvements are based on facts, not assumptions. Supporting Lean and continuous improvement initiatives

Validate Improvements and Drive Continuous Optimization

Gazpacho Analytics allows you to compare operator movement over time and validate the impact of changes.

You can:

• Reduce unnecessary motion and improve ergonomics
• Compare “as-is” and “to-be” scenarios
• Optimize layouts and work sequences
• Support continuous improvement with data-driven insights

Measurable Results

With Gazpacho Analytics, manufacturers achieve:

• Reduced unnecessary operator movement
• Improved productivity and workflow efficiency
• Better ergonomics and safer work environments
• Reduced bottlenecks and improved flow
• Faster, data-driven decision-making

Gazpacho Analytics turns operator movement data into measurable performance improvements.

Optimizing Operator Movement with Data

At Virtual Manufacturing’s Hackefors factory, we combined Viscando 3D&AI with Gazpacho Analytics to track operator movement, material flows, and workflows. By visualizing walking paths with spaghetti diagrams, highlighting high-traffic zones with heatmaps, and analyzing time spent in critical areas, we identified bottlenecks and unnecessary motion. These insights provided a clear, data-driven foundation for layout improvements, boosting efficiency, reducing waste, and improving the working environment.

Would you like to know more contact Daniel Wigren for Europe, Richard Gould for UK and Irland, Pontus Rosengren for rest of the world

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Real-Time Energy Monitoring for Efficient Production that Optimize Your Energy Usage and Costs

In modern manufacturing, energy is not just a cost, it’s a strategic resource. Gazpacho Energy provides real-time energy monitoring, helping production teams identify hidden inefficiencies, reduce waste, and improve operational sustainability. By capturing precise energy data from machines, lines, and stations, you can see exactly when and where energy is consumed.

Solve Production Energy Challenges

Manufacturers face challenges like inconsistent energy consumption, high standby usage, and energy peaks during start-up. Gazpacho Energy makes these visible, allowing you to:

• Detect and reduce hidden energy waste
• Link energy usage directly to production activities
• Prevent costly inefficiencies without impacting output

From Insight to Action

With intuitive dashboards, Gazpacho Energy delivers updates every 30 seconds, showing consumption in amperes, kWh, and cost. You can take proactive action through automated alerts, email reports, or guided recommendations. This enables energy optimization, smarter production decisions, and measurable ROI.

Support for Sustainability and ISO 50001

Gazpacho Energy helps organizations meet sustainability targets and ISO 50001 requirements. By analyzing energy patterns, you can prioritize upgrades, plan investments, and set realistic Net Zero goals.

Who Benefits

• Engineering & Production: Optimize processes, reduce waste, and improve efficiency
• Management & Sustainability Teams: Track KPI progress, make informed investment decisions
• Maintenance: Identify underperforming equipment and schedule improvements

With Gazpacho Energy, data drives decisions. Reduce costs, improve sustainability, and make energy efficiency a competitive advantage.

Case Study: Data-Driven Energy Insights for Smarter Production

Wallåkra Mekaniska partnered with Virtual Manufacturing to uncover hidden energy patterns and turn real-time data into actionable insights. By installing Gazpacho Energy, they gained live dashboards, historical tracking, and machine-level analytics, enabling informed decisions that reduce costs, improve efficiency, and support sustainability.

Read the full case study

Would you like to know more contact Daniel Wigren for Europe, Richard Gould for UK and Irland, Pontus Rosengren for rest of the world

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In Swedish

Support Your Teams with Smarter Operational Management Using Digital Pulse Boards

Mevisio transforms how manufacturing teams manage operations by digitizing workflows, centralizing data, and enabling real-time collaboration across your production floor. Using digital pulse boards, teams gain actionable insights from frontline operations, streamline communication, and make data-driven decisions that optimize efficiency and reduce waste.

Optimize Operations and Eliminate Inefficiencies

Traditional tools like manual whiteboards, spreadsheets, and disconnected systems can create bottlenecks and keep teams reactive. Mevisio replaces these fragmented approaches with a single, intuitive platform. With Mevisio, you can track production metrics, monitor deviations, and ensure smooth daily operations, improving visibility and accountability across your entire team.

Boost Operational Efficiency

For manufacturing leaders, operational excellence drives profitability. Mevisio empowers teams to move beyond manual routines by providing a customizable platform that delivers real-time insights, reduces downtime, and accelerates problem-solving. Digital pulse boards support daily management, structured problem-solving, and employee engagement, driving measurable improvements in Lean practices, waste reduction, and operational performance.

Take Full Control of Your Production Floor

Mevisio replaces outdated whiteboards with dynamic dashboards tailored to your production environment. Monitor KPIs, follow up on deviations, and manage daily operations efficiently. From standups and shift handovers to safety tracking and continuous improvement, digital pulse boards keep your teams aligned, proactive, and focused on results.

Visualize, Measure, and Improve

With Mevisio, teams can visualize workflows, identify bottlenecks, and track resource usage in real time. The platform allows aggregation of data across multiple boards, giving managers a holistic view of operations while maintaining flexibility for local execution. Mevisio drives Lean initiatives, enhances collaboration, and ensures that every decision is informed by data.

Scaling Lean Success Globally and Locally

Mevisio standardizes Lean practices while supporting local workflows. By linking operational performance to digital pulse boards, teams can measure improvements, monitor progress, and sustain change across sites and departments. The platform helps overcome common barriers like siloed communication, inconsistent follow-up, and resistance to change.

Why Mevisio Matters

• Centralize production data with digital pulse boards
• Streamline daily standups, problem-solving, and safety routines
• Reduce waste, downtime, and manual errors with real-time visibility
• Support Lean initiatives, continuous improvement, and operational excellence
• Align production metrics with strategic business goals

Mevisio empowers manufacturers to turn production challenges into measurable results, making operations smarter, more efficient, and fully connected.

In Swedish

Transform Workstations and Boost Production Efficiency

In modern manufacturing, human errors, long training times, and inconsistent execution can limit efficiency, quality, and throughput. Arkite is an Operator Guidance Platform that turns your workstations into interactive, digital environments, guiding operators with augmented reality (AR) instructions, real-time validation, and smart sensor feedback. The result? Reduced errors, faster onboarding, and measurable improvements in operational performance.

Delivering Results Across Your Operations

With Arkite, companies can standardize and digitize assembly, picking, kitting, and cabling processes while maintaining flexibility for multi-product lines. Operators receive step-by-step visual instructions directly at the workstation, ensuring first-time accuracy and minimizing rework. By capturing data at every step, Arkite enables traceability, continuous improvement, and data-driven decision-making across the shop floor.

• Reduce Errors and Rework: AR-guided instructions and sensor validation ensure tasks are performed correctly every time.
• Accelerate Onboarding: New operators quickly learn processes, shortening the training curve and maintaining high skill levels.
• Increase Productivity: Digital work instructions eliminate paper manuals and inefficiencies, allowing teams to focus on value-added tasks.
• Enhance Traceability: Integration with MES systems provides full documentation of components and actions for quality compliance.

Flexible, Scalable, and Data-Driven

As an Operator Guidance Platform, Arkite adapts to both traditional and complex production environments, including discrete manufacturing, electronics, medical devices, and pharmaceuticals. Whether improving assembly accuracy, standardizing SOPs, or supporting flexible workforce deployment, Arkite provides measurable value while enabling continuous improvement.

By combining AR instructions, smart sensor validation, and digital traceability, Arkite empowers operators, supports management oversight, and drives tangible results for manufacturing performance. Companies adopting Arkite see improvements in efficiency, quality, and throughput, delivering a measurable impact on operational excellence and profitability.

Streamline Manufacturing Processes with an Integrated Software Suite

In Swedish

AVIX is a complete software suite for the analysis and optimization of design and manufacturing processes. It is a software that allows you to gather all data, such as method and time studies, line balancing, and FMEA, in one place and within one system. This makes it easier to administer and update. AVIX can also easily exchange information with other systems via XML format.

The information is interconnected in AVIX. A change in the time study for a workstation directly affects the balance of the line and the work instructions. This is a tremendous advantage as it simplifies what is often a significant challenge for the production engineering department: keeping the information up-to-date and accurate. Otherwise, there is a significant risk that the foundation becomes obsolete, and everyone loses confidence in instructions and documentation. We call it production engineering efficiency!

AVIX METHOD – Method and time study

AVIX Method uses MTM-based standard times (or other type of stopwatch measurements) to perform time study analysis of work operations to create the data needed for line balancing and product calculations.

A simple and rapid study provides detailed information, ranging from times of individual work operations to full production line processes. The time base can be used for time data management (TDM) as well as improvement work, capacity calculations, line balancing, work instructions or simply as a basis for decision making.

Or, put another way, how can you make decisions about what and how to improve, if you don’t have the necessary facts about the processes? – AVIX Method helps you analyse and manage this information in a logic and visual way.

AVIX RESOURCE BALANCE – Efficient flow optimization

In AVIX Resource Balance the work operations are balanced between the different workstations and internally between the operators. AVIX Resource Balance has the capability of handling multiple operators as well as man-machine operations.

AVIX visualizes (graphically and numerically) losses caused by an unbalanced workflow. 
The final outcome from the software is reduced balancing losses and the possibility to create new work instructions.

Combining AVIX Resource Balance with AVIX Ergo makes is possible to apply the line balancing activity not only from a workload perspective, but also from an ergonomic perspective. Utilizing the ergonomic model REBA, you can visualize the balance result in terms of both workload (time) but also physiological stress levels.

AVIX SMED – Single minute exchange of die

Reduce set-up time and produce more! Faster and more efficient set-up results in less downtime & increased productivity.

Consider the optimal set-up as a pit-stop in Formula-1. It is performed quick and correct. SMED is one of the many lean production methods for reducing waste in a manufacturing process.

Gain control and visual overview of the setup process with AVIX SMED.

AVIX FMEA – Failure mode and effect analysis

Use AVIX FMEA to perform powerful P/D-FMEA analysis for products and processes in a logic and simple way.

Search, find and give priority to the right FMEA actions to prevent quality deviations being process or design related. Different type of reports can easily be created, e.g. FMEA and Control Plan reports with a clear link the the process steps.

Being a software solution, AVIX makes the information visual and more logic to work with by connecting to the process via video and to the product via its product assembly structure. AVIX also gives the necessary support working with the new and more complex VDA/AIAG methodology by visualizing the Failure and Function net.

Streamline Your Manufacturing with Visual Components at Virtual Manufacturing

At Virtual Manufacturing, we specialize in turning theory into practice through advanced simulation technology. Using Visual Components, a world-leading platform for 3D simulation in the manufacturing industry, we elevate your production process to the next level. Our goal is to optimize every aspect of your manufacturing, from design to delivery, by offering tailored solutions that meet your specific needs.

DES & Flow Simulation: Foresee the Future, Today

By implementing DES (Discrete Event Simulation) and flow simulation with Visual Components, Virtual Manufacturing provides unmatched insight into your production process. These tools allow us to model, simulate, and analyze complex manufacturing systems in an intuitive and powerful way. The result? Reduced costs, improved efficiency, and a faster time-to-market for your products.

Revolutionize with Layout and Robot Integration

Visual Components offers not only DES and flow simulation but also advanced features for layout planning and robotics integration. With these powerful tools, we can:

• Design and optimize production layouts in 3D to maximize space efficiency and workflows.
• Simulate and validate robotic applications for automation, including picking, placing, and assembly, ensuring that robotic investments deliver maximum returns.
• Integrate robotic technology with existing production lines to increase productivity and reduce manual labor.

These features enable us to create a comprehensive view of potential improvements and innovations in your manufacturing process, leading to greater flexibility and lower production costs.

Why Choose Virtual Manufacturing?

With experience and a passionate commitment to innovation, Virtual Manufacturing is your ideal partner for implementing Visual Components. Our team of experts works closely with you to understand your specific challenges and goals, and together we create a customized solution that takes your production to new heights.

Are you ready to discover how Visual Components can revolutionize your manufacturing process with its extensive DES, flow simulation, layout planning, and robotics integration? Contact us at Virtual Manufacturing today for a consultation. Let us build the future of manufacturing together.

Digitalization for Manufacturing and Logistics with Quuppa’s Location Services

In Swedish

In manufacturing, operational managers must tackle a multitude of logistical challenges. The primary issue is the lack of data visibility, complicating everything from warehouse management to shipment tracking. Without visibility across the entire supply chain, items often end up misplaced during various production stages, and time is wasted manually trying to trace goods and equipment.

Challenges in Traditional Logistics

Individual stakeholders in a supply chain often use their internal management systems and communication channels, as opposed to a centralized reporting and tracking system, resulting in locked data that obscures the bigger picture regarding the status and location of an asset.

The Need for Centralized Asset Tracking

The resulting bottleneck highlights the need for a centralized system for asset tracking, which can only be achieved through a transition to digitalization in logistics. This is why Quuppa has been working on developing Real-Time Location Systems (RTLS), enabling assets to be located, tracked, and analyzed within indoor facilities.

Quuppa’s Solution: Real-Time Location and Positioning

With Quuppa’s precise positioning system, an asset’s exact location can be made clear in real-time, simplifying and streamlining asset retrieval. Unlike other RTLS platforms, Quuppa’s system can locate tags and various other devices with Bluetooth (e.g., mobile phones and scanners) down to a 10-centimeter level, transmitting and receiving signals in metal-dense spaces, making it uniquely suitable for warehouses and other challenging environments.

Benefits of Quuppa’s System

Quuppa’s system also provides an accurately updated inventory across multiple locations, whether it’s for tools, packages, or equipment, ensuring you know exactly what you have and where you have it. All this data is integrated into a single centralized platform, allowing easy configuration, management, and monitoring of multiple sites, enhancing scalability.

QUUPPA