Simulation Before Installation: What to Model
What simulation is good at
- Checking reach across the whole working envelope, including tool changes.
- Estimating cycle time for motion, and finding collisions before they happen.
- Comparing two layouts on the same takt time requirement.
- Producing a video that operations can react to — useful, and honest feedback.
What simulation cannot tell you
It cannot predict how a human will hand you a part, how much the material varies, or how long a vision system takes to settle in real lighting. Treat the simulated cycle time as the floor, then add real handshakes and a margin before you promise a number to production.
| Model input | Where to get it | Why it matters |
|---|---|---|
| Part geometry and weight | Drawings plus a scale | Payload and gripper choice |
| Feeder behaviour | Video of the real line | Stability of presentation |
| Machine handshake time | PLC trace | The hidden part of the cycle |
| Operator action | Time study | Human tasks that remain |
Use the model as a design tool, not a promise
The most valuable output is not the animation but the list of collisions, awkward poses and unreachable points. Fix those on screen. Every hour spent there is cheaper than an hour spent with a crane in the plant.