Brownfield

Rebuild without breaking operations.

Plan the sequence of moves and validate constraints so you can execute changes with minimal downtime and stable delivery.

Why this matters

Typical pains

A clear view of what breaks in the real world—so the model is built for what actually happens.

Relocations cause cascading issues across flow and buffers.

The real constraint shows up only after changes are live.

Teams lack a shared model of what changes when.

Outcomes

What improves

A measurable way to evaluate scenario variants and the decisions you will make.

Downtime

reduced via stepwise planning

Flow

stabilized with buffer and path validation

Execution

clearer with visual sequencing

Deliverables

What you get

A decision-ready package: model, scenarios, and an actionable rollout path.

Deliverables

  • Sequenced relocation plan with constraints
  • Animation to communicate steps and dependencies
  • Simulation highlighting bottlenecks and transport paths

Recommended capabilities

Start with the minimum set needed for the outcome, then scale to historical and live data as the use-case matures.

VisualizationAnimationSimulation

Proof

Case studies

Real scenarios, shown in full under this use case.

Facility expansion and relocation planned with Digital Twin

Automotive components (manufacturing + intralogistics)

Expansion plan with step-by-step relocation

Context

A production site expands with a new hall, requiring careful relocation and sequencing to maintain output.

Task

Plan a staged relocation of machines and material flow so production continues without disruption, while validating buffer capacity and intralogistics continuity.

Work

  • Built a 3D representation of the facility and added the new hall area.
  • Animated process sequences to validate relocation order.
  • Modeled material flow with technological times and constraints.
  • Simulated variants to find bottlenecks and transport path losses.

Results

  • A relocation sequence that preserves planned output.
  • Improved final machine layout compared to the initial assumption.
  • Identified transport-path extensions as a major source of losses.

Benefits

  • Lower risk of disruption during expansion
  • Faster decision-making through visual and scenario-based validation
  • Better alignment across operations and leadership