Key takeaways
Client: A leading Chinese OEM; Field: Simulation. Using cycle simulation and digital twin, new line commissioning time dropped 35% and throughput rose 18%.
Background
The client was building a new welding line for an NEV model, facing unacceptable cycle times, frequent robot interference and expensive retrofits — all needing virtual validation before production.
Solution
- Built a 1:1 digital twin of the entire line covering 62 robots and conveyor systems
- Ran cycle simulation on critical stations to identify bottlenecks and redistribute welding tasks
- Predicted welding distortion with thermo-mechanical simulation to optimize fixtures and sequence
- Delivered a cyber-physical twin mirroring live line status after commissioning
Results
35%Shorter commissioning
18%Throughput increase
62Robots simulated
0Interference incidents