S01E16: Digital Twin Factory Planning and Simulation

What if you could run your new factory for a year before the first brick is even laid? Stop making multi-million dollar investment decisions based on static blueprints and start testing your future operations in a risk-free virtual world.

Costly design flaws—from unbalanced lines to cramped logistics spaces—are often discovered only after a new plant is already running, forcing expensive and disruptive changes. In this episode of Factory on Air, we show you how to avoid these mistakes. Discover how digital twin simulations allow you to design, test, and optimize your new factory layout before construction begins, saving you millions and ensuring efficiency from day one.

▶️ In This Episode, You'll Discover:

• The High Cost of Bad Design: The most common and expensive mistakes made during the factory planning phase, including unbalanced production lines, inefficient logistics, and poor ergonomics.
• Your Virtual Sandbox: How Digital Twin simulations allow you to test different layouts, model material and people flows, and identify potential bottlenecks before they become costly physical problems.
• Designing with Data: Why using operational data is the foundation for a 'tailor-made' factory that is perfectly optimized for space, ergonomics, and safety, preventing both cramped conditions and wasted area.
• Proven Results: Learn how a manufacturer saved 1.2 million PLN by using simulations to avoid building a needless warehouse, and how an automotive plant cut its required production space by 20% without losing efficiency.
• The DBR77 Approach: See how our platform creates a 3D digital twin of your planned factory, allowing you to test scenarios and analyze operational flows to guarantee a successful launch.

🚀 Take the Next Step

Planning a new facility or a major production line overhaul? Schedule a no-obligation strategy session to discover how you can de-risk your investment and guarantee efficiency with a Digital Twin simulation.

Book your session: https://meetings.hubspot.com/bartek-straszak

About Factory on Air

Factory on Air is the podcast for Professional Rebels in manufacturing. We challenge the status quo and provide practical insights for leaders who want to build the factories of the future, today. Subscribe for expert interviews, deep dives into smart factory technology, and actionable strategies to unlock a new level of performance.

🔔 SUBSCRIBE so you never miss an episode!

#FactoryDesign #DigitalTwin #Greenfield #SmartFactory #Manufacturing #CAPEX #Simulation #Industry40 #DBR77