All automation systems deliver at commissioning.
– The real challenges often come later.
When the product mix changes or new requirements arise, many systems become difficult to upgrade – without disrupting production or taking unnecessary risks.
At Shape, we are now working systematically with simulation models of already delivered systems to:
- validate new palletizing patterns offline
- implement improvements without production downtime
- extend the lifetime of existing investments
This is a Shape-driven initiative, with the ambition to make simulation a natural part of the entire customer journey – even after the system is up and running.
Do you recognize the challenge?
At Shape Process Automation, simulation has long been part of our engineering toolbox. Traditionally, it has been used to study robot movements and support offline programming. A few years ago, however, we took a strategic step forward: we began building simulation competence internally to support complete production systems — not just individual robots.
The decision was both technical and business-driven. We conducted a thorough analysis of how simulation could create additional customer value while strengthening profitability in our own operations. We had previously relied on external consultants for larger or more complex system simulations. While this provided results, we realized that much of the real value lies in the modelling process itself — in asking the right questions, clarifying constraints, and iterating quickly together with the customer. That value is difficult to capture when simulation is outsourced.
By building our own competence and working methods, we gained the ability to create and refine models rapidly. This allows us to evaluate concepts earlier, validate assumptions, and make informed design decisions before physical implementation. It also improves ROI internally: as our team becomes more efficient, we can develop more simulation models per engineer and license — a scalability effect that is lost when simulation is purchased externally.
From Concept Validation to Operational Development
The true potential of simulation becomes clear not only during system design, but also after delivery.
In a recent case involving a high-density palletizing system handling multiple product types, we delivered two mirrored systems to the customer. At handover, a number of products were programmed and operational. As new product variants were introduced, new PLC programs and robot jobs needed to be implemented.
Instead of validating changes directly in the live production environment, we used a virtual model of the installed system.
The setup mirrors the real system closely:
- The exact same PLC code runs in Siemens PLCSim Advanced.
- The same robot jobs run in MotoSim EG-VRC.
- The HMI operates in an emulator, allowing new recipes to be loaded exactly as in the real installation.
- A 3D model, based on CAD data, represents the mechanical structure.
- Visual Components connects PLC, robot logic, sensors and actuators, combining discrete process simulation with physical simulation to reproduce realistic behaviour.
Signals between PLC, robot and system flow through the model just as they do in reality. Servo movements and sensor logic are simulated. The model is validated using products already running in production to ensure that simulated behaviour corresponds to the physical system.
This approach enables us to validate new products, optimize pallet patterns and adjust logic — all without interrupting production.
Expanding the Value Proposition
Building digital models that closely reflect delivered systems opens several strategic opportunities.
Before delivery, virtual FAT can be performed to test critical functions in advance. In the near future, certain systems may be delivered together with a corresponding simulation model as part of the standard package.
In the shorter term, simulation enables:
- Operator training in a realistic environment
- Offline programming for new products or system updates
- Improved support through access to a functional digital counterpart
Over time, this development naturally leads toward digital twin concepts, where the virtual and physical systems coexist as complementary assets. We already see increasing requirements for virtual FAT in customer projects — a clear indication that market maturity and technology readiness are now aligned.
A Long-Term Perspective
For us, simulation is not a visual sales tool. It is a strategic capability that strengthens decision-making, reduces risk and extends the lifecycle of our customers’ investments.
As automation systems grow more complex and production flexibility becomes increasingly critical, digital models will play a central role in ensuring sustainable performance over time.
We believe the industry is reaching a point where simulation-based methods are no longer optional for complex systems — they are expected.
And we intend to be at the forefront of that development.
Would you like to explore how simulation could extend the lifecycle and flexibility of your production system?
Anders Jönsson leads the simulation initiative at Shape Process Automation, with a background in advanced modelling and automation systems. He works closely with customers to develop practical, high-value applications of digital models across the system lifecycle.
Feel free to connect with Anders on LinkedIn or contact Shape to discuss how simulation-based methods can support your next step.