SIMS 64 Västerås, Sweden, September 26-27, 2023

Visualization of Industrial Production Processes using

3D Simulation Software for Enhanced Decision-Making
Akshay Goyal

Mälardalen University and Mälardalen Industrial Technology Centre,

akshay.goyal@mdu.se

Abstract

This paper explores the use of 3D simulation software for visualizing industrial production processes and its potential to
enhance decision-making for improved production efficiency, quality, and profitability. Industrial production processes are
complex and involve many variables and factors that can interact in unpredictable ways. Visualization helps to simplify these
complex interactions, identify patterns and relationships, and enable more informed decision-making.
The research question that guides this paper is: How can the use of 3D simulation software for visualization of industrial
production processes improve decision-making and optimize production efficiency, quality, and profitability? This paper will
investigate the benefits and challenges of using 3D simulation software for visualizing industrial production processes,
including the ability to identify bottlenecks, and optimize the production process. Further, the paper examines the role of
visualization in enabling more informed decision-making, including the ability to analyze production data and make data-
driven decisions. To illustrate this, an industrial automation case study consisting of a manufacturing industry modelled in a
3D simulation software has been presented.
The results of this 3D-simulation model provide insights into the advantages and disadvantages of utilizing 3D simulation
software to visualize industrial manufacturing processes. The article further presents the significance of these findings for
production managers, engineers, and decision-makers. Thus, the purpose of this study is to help readers understand how using
3D simulation software for visualization of industrial production processes can improve decision-making and optimize
production efficiency, quality, and profitability.
Keywords: Industrial production processes, 3D simulation software, visualization, decision-making, production efficiency,
industrial automation, data-driven decisions, manufacturing industry, optimization.

1. Introduction Visualization is the use of graphical or pictorial

representations to convey complex information in an
Industrial production processes are central to the intuitive and easily understandable way. In the
production of goods in the manufacturing industry. context of industrial production processes,
A series of activities involved in converting raw visualization help to simplify complex processes,
materials into finished goods using various make patterns and relationships more evident, and
equipment, tools, and machines are referred to as enable more informed decision-making (Wang et al.,
industrial production processes. Material handling, 2015). In the context of industrial production
assembly, packaging, and quality control are processes, visualization helps to provide a clear
examples of these processes. Optimizing industrial understanding of the process flow, identify
production processes is critical to achieving better bottlenecks, simulate, and test different scenarios,
production efficiency, quality, and profitability. This and optimize resource allocation. Additionally,
is because inefficient and suboptimal production visualization can help decision-makers to
processes can lead to bottlenecks, delays, and errors, understand the impact of different decisions on
which can result in increased costs, decreased production processes and outcomes and choose the
quality, and reduced competitiveness (Xu et al., best course of action accordingly (Molenda et al.,
2021). To overcome these challenges, 2019).
manufacturers are increasingly turning to
technology to improve their production processes. In industrial production processes, there are often a
3D simulation software is one such technology that large number of variables and factors to consider,
has been gaining popularity in recent years, as it such as machine parameters, production rates, and
enables manufacturers to visualize and analyze their quality metrics (Xu et al., 2021). These factors can
production processes in a virtual environment before interact in complex ways, making it difficult to
implementing changes in the physical world (Abidi understand and optimize the production process
et al., 2020). (Molenda et al., 2019). Visualization can help to
simplify these complex interactions by presenting
the information in a way that is easier to understand
SIMS 64 Västerås, Sweden, September 26-27, 2023

and analyze. Furthermore, visualization is used to research articles was conducted to gain insights into
identify patterns and relationships that may not be visualization techniques, simulation software, and
apparent from raw data. For example, by plotting decision-making methodologies. The review
machine performance over time, it may be possible included a range of sources including scholarly
to identify recurring issues that are impacting articles, research papers, and industry reports to
machine production efficiency (Atmakuri et al., understand the current state of research in the field.
1993). By presenting this information graphically, it Data collection for this study involved gathering
is easier to identify patterns and make informed relevant information from various sources.
decisions about how to address the issues. Keywords related to industrial production processes,
visualization, and decision-making were used to
Through displaying information in a way that is identify peer-reviewed articles that contributed to
clear and accessible, visualization also aids in the research area. These articles were carefully
enabling more informed decision-making (Atmakuri selected and analysed to extract valuable insights.
et al., 1993). This can assist stakeholders in making
more informed decisions by helping them
understand the effects of various actions on
production efficiency, quality, and profitability
(Yang et al., 2021). Therefore, the topic of
visualization of industrial production processes
using 3D simulation software for enhanced decision-
making is important because it enables Figure 1: Research Method
manufacturers to optimize their production
processes, leading to better production efficiency, The software Visual Components® has been utilized
quality, and profitability. By visualizing production by the author to develop the 3D simulation model.
processes in 3D simulation software, manufacturers The model represents an industrial production
can identify bottlenecks, test different scenarios, and process consisting of injection moulding machines,
make data-driven decisions before implementing series of conveyor belts, robots and a warehouse for
changes in the physical world. This can lead to storage. The model was developed based on the
reduced costs, improved quality, and increased specific requirements and specifications of the case
competitiveness, all of which are critical factors for study and a dynamic representation of components
success in the manufacturing industry. Hence, the flow has been visualized. The experiment design
research question has been formulated as follows: phase involved defining the simulation resources
and parameters. Key variables, such as production
How can the use of 3D simulation software for volumes, cycle times, and system constraints, were
visualization of industrial production processes determined to create a realistic simulation
improve decision-making and optimize production environment. The experimental design aimed to
efficiency? capture the complexities and dynamics of the
industrial production process under study. The
2. Methodology simulation model was executed to replicate the
production operations. During the simulation run,
The problem addressed in this study is the need for process states, utilization rates, and performance
enhanced decision-making in industrial production metrics were recorded. This data provided valuable
processes. Traditional methods of decision-making insights into the functioning of the production
may lack comprehensive insights into the complex system and allowed for a detailed analysis of the
dynamics of production systems. Therefore, there is simulation results.
a growing interest in utilizing 3D simulation
software to visualize industrial processes and The collected data was analysed to answer the
improve decision-making capabilities. research question posed in the study. The analysis
focused on evaluating the effectiveness of the
The purpose of this study is to explore the potential visualization of industrial production processes
benefits of using 3D simulation software for using the 3D simulation software. Performance
visualizing industrial production processes and metrics, such as throughput, cycle times, and
examine its impact on decision-making. By resource utilization, were examined to assess the
investigating this area, the study aims to provide impact of visualization on decision-making. The
valuable insights and practical recommendations for results were interpreted to draw conclusions and
improving decision-making in industrial settings. provide practical recommendations. Based on the
Figure 1 illustrates the research methodology analysis of the simulation results, conclusions were
involved in the development of the simulation drawn regarding the effectiveness of using 3D
model. A comprehensive review of scholarly and simulation software for visualizing industrial
SIMS 64 Västerås, Sweden, September 26-27, 2023

production processes and enhancing decision- information and enabling real-time interaction
making. The study provides insights into the benefits (Molenda et al., 2019). By visualizing the processes
and limitations of visualization techniques and in a virtual environment, decision-makers can better
offers recommendations for further improvements in grasp the flow of materials, detect inefficiencies or
decision-making practices within industrial settings. bottlenecks, and make data-driven decisions to
optimize the system.
2.1. Simulation of Industrial Production
Processes 2.2. Building 3D Simulation Model
Industrial production processes are fundamental in
the manufacturing industry, encompassing a series The use of a 3D manufacturing simulation model
of stages and steps that convert raw materials or provides a valuable tool for simulating and
components into finished products (Molenda et al., analyzing basic manufacturing procedures within a
2019). These processes involve crucial operations virtual environment. This technology leverages 3D
such as material handling, assembly, packing, and visualization, which utilizes computer technology to
quality control (Chawla & Banerjee, 2001), which depict real-world objects in a virtual space,
have been recognized as essential for simulating surpassing the limitations of two-dimensional (2D)
manufacturing processes. However, the complexity images in representing complex spatial information
of these processes, often involving multiple (Xu et al., 2021). By incorporating real-time
interconnected systems and subsystems, presents interaction capabilities, the 3D visualization
challenges in comprehending and optimizing them enhances the immersive experience and enables
effectively (Atmakuri et al., 1993). users to engage with the simulated environment
effectively. The implementation and integration of a
Optimizing industrial production processes holds 3D simulation model involve several important
immense value as it has the potential to improve steps. Key considerations during this process
various aspects, including production efficiency, include defining resource parameters, selecting
product quality, and overall profitability (Yang et appropriate equipment, establishing fundamental
al., 2021). By identifying and addressing simulation logic, and incorporating relevant
bottlenecks, minimizing waste, and maximizing production data (Xu et al., 2021). These elements
throughput, optimization efforts can lead to are crucial for creating an accurate and realistic
significant cost savings, enhanced customer representation of the manufacturing system within
satisfaction, and increased competitiveness in the the simulation model.
marketplace. However, achieving optimization in
The resource parameters encompass various factors
industrial production processes is not without its
such as material properties, production capacities,
obstacles. Challenges such as demand variability,
and operating constraints. These parameters define
equipment breakdowns, and workforce availability
the characteristics and capabilities of the resources
can impede the optimization journey, necessitating
involved in the manufacturing process, enabling the
the adoption of advanced technologies to overcome
simulation model to accurately reflect their behavior
these hurdles (Chawla & Banerjee, 2001; Yang et
and interactions (Chawla & Banerjee, 2001). The
al., 2021). In this context, the utilization of 3D
selection of equipment involves identifying and
simulation software and visualization techniques
configuring the machinery, tools, and systems that
emerges as a powerful solution. These technologies
are integral to the manufacturing process. By
enable a deeper understanding and effective
modelling these equipment components within the
management of industrial production processes by
simulation, their functionalities and interactions can
providing insights into complex interactions and
be evaluated and optimized (Wang et al., 2015).
facilitating informed decision-making. 3D
Fundamental simulation logic refers to the
simulation software allows for the creation of virtual
underlying principles and algorithms that govern the
environments where manufacturing procedures can
behavior and dynamics of the simulated
be simulated, analyzed, and optimized (Chawla &
manufacturing process.
Banerjee, 2001). By replicating real-world
scenarios, these simulations enable manufacturers to Creating a 3D simulation of an industrial production
test different scenarios, evaluate the impact of procedure entails multiple processes (Figure 2).
process changes, and identify potential areas for First, describe the simulation's scope and objectives,
improvement. outlining the precise goals to be attained. Next,
collect relevant data about the manufacturing
Visualization techniques, particularly in 3D, offer a process and identify the components and processes
more intuitive and comprehensive representation of that must be modelled. Choose a 3D simulation
the production processes. They surpass the program that matches the project's criteria. Create
limitations of traditional two-dimensional (2D) the simulation model by combining the acquired
images by providing a richer visualization of spatial data and modelling the manufacturing line's
SIMS 64 Västerås, Sweden, September 26-27, 2023

components and procedures. This includes process that cannot be seen in depth on the 3D
developing 3D models, setting material flow rules, simulation of the production site (Xu et al., 2021).
and determining timing and sequencing. Validate
2.4. Decision Making from simulation model.
and improve the simulation model by comparing it
to real-world data and making necessary
Effective decision-making is crucial in industrial
modifications. Analyze the simulation findings to
production processes as the decisions made during
find areas for improvement and to enhance decision-
production can significantly impact efficiency,
making.
quality, and profitability (Yang et al., 2021). It is
essential to have a clear understanding of the
production processes and the consequences of
different decisions on the outcomes. This is where
the utilization of 3D simulation software and
visualization techniques proves valuable (Xu et al.,
2021). These tools enable manufacturers to create
virtual representations of their production systems,
visualizing the flow of materials, machines, and
resources. Through simulation and visualization,
decision-makers can assess different scenarios,
Figure 2: Building a 3D simulation model. identify potential issues, and make informed
decisions before implementing changes in the
2.3. Visualization Techniques for Simulation physical world (Yang et al., 2021).

The use of virtual reality (VR), augmented reality Figure 3 presents a conceptual model for decision
(AR), and visual simulation technology allows to making which has been designed to capture an
create a simulation model that can replicate real expert's knowledge using simple and understandable
elements, without relying on complex artificial
production scenarios in a safe environment (Xu et
intelligence or process representation (Garcia-
al., 2021). By inputting actual production data into
the model, it is possible mimic on-site production in Crespo et al., 2010). Instead, real-life situations
real-time. This technology helps us convert complex have been focused, which occur during the
execution of a manufacturing process, which
problems into more understandable ones (Xu et al.,
consider facts (data), action (resources) and
2021). Furthermore, the simulation model provides verification (checking the results from action are
a visual representation of production or valid) through the process of making a decision.
manufacturing processes using terminal equipment
(Abidi et al., 2020). They have further presented
that by analysing and optimizing data, refining the
mathematical model; and a closed-loop control and
monitoring system can be created. This means that it
enables to continuously monitor and adjust the
production process based on the information
provided by the simulation model.
A new strategy to generalizing the manipulation of
Figure 3: Decision Making Conceptual Model
industrial process simulation is explored (Abidi et
(Garcia-Crespo et al., 2010)
al., 2020), where it is possible to visualize and
engage with an industrial simulation model. It also The aspect of decision making becomes important
enables industrial actors to visualize the operation of once there is an access to the real-time data through
their factories which is based on virtual reality the created simulation model. Furthermore, Garcia-
technology and behavioural programming of the Crespo et al., (2010) in their research have
production flow. presented this ontology for describing the
automation of decision-making processes in the
Xu et al., (2021) in their research describe the
manufacturing process setting. In that, they have
frame of visualization application, where they show
highlighted the importance of having a semantic
the entire process starting from Cyber Physical
representation of different manufacturing processes
System (CPS) to formulating the visualization
which further enable data representation strategy
platform. Within this VR and AR have been utilized
based on with the process of decision making is
for visualizing the created simulation model for the
enabled.
purpose of scheduling optimization and real-time
monitoring. This results in a 3D recreation of
industrial processes that depicts the production
SIMS 64 Västerås, Sweden, September 26-27, 2023

3. Case Study Here, another robot is responsible for picking up the

boxes and organizing them on the pallets.
This section presents a 3D simulation model as a
case study to showcase the application in real-world The palletization process incorporates its own
situation. This section further highlights the process conveyor system, ensuring a smooth flow of
of decision making and finally presents the results operations. Within the palletization process, the
from the simulated model. plastic wrapping and pallet stacking procedures take
place, further enhancing the stability and protection
3.1. Case Description of the palletized goods. Once the pallets undergo the
stacking process, a stacker crane is employed to
Simulation modelling is essential for streamlining hoist them and place them in the designated
manufacturing procedures and increasing overall warehouse for storage. This ensures efficient
productivity in the area of industrial automation. utilization of space and ease of access when
Industrial systems can be accurately modelled and retrieving the pallets for distribution or subsequent
analysed to find opportunities for improvement production stages. Through the integration of 3D
using cutting-edge 3D simulation software. This simulation software, this case study showcases the
study presents a simulation model of an industrial visualization of an industrial automation scenario in
automation case in a sector of manufacturing with a the manufacturing industry. The subsequent sections
focus on plastic injection-moulded basket of this paper will delve into the benefits, challenges,
manufacturing. The purpose of this study is to and decision-making aspects associated with the
demonstrate how decision-making may be improved visualization of this simulation model.
in the context of industrial production processes by
using visualization and simulation approaches. The
simulation model depicts a comprehensive
representation of the production shopfloor,
showcasing various interconnected components and
processes.

Figure 5: Different zones in the production

shopfloor

The production shopfloor in the simulation model

has been divided into four distinct zones: Zone 1,
Zone 2, Zone 3, and Zone 4. Each zone encompasses
Figure 4: 3D model of the production shopfloor specific functional procedures and components that
contribute to the overall industrial production
Figure 4 provides an overview of the shopfloor, process. Figure 5 provides a visual representation of
offering a visual representation of the industrial the layout and arrangement of these zones within the
automation case. The simulated model consists of production shopfloor. The division of the production
two injection moulding machines, which are shopfloor into these zones and the incorporation of
coupled by a conveyor system. This conveyor specific components and processes within each zone
system facilitates the seamless transfer of the provide a comprehensive representation of the
manufactured items (plastic baskets), between the industrial production model.
machines. Subsequently, the baskets undergo a
visual inspection process to identify any poor- Zone 1 serves as the initial stage of the production
quality elements. The conveyor system also enables line, comprising two injection molding machines, a
the transportation of the approved baskets for further robot positioned overhead between the machines,
processing. To streamline the packing process, a and a conveyor transport system. The robot
robot is strategically placed between the two efficiently picks up the moulded baskets from the
conveyor systems. This robot plays a vital role in injection molding machines as the machine doors
efficiently packing the baskets into boxes. Once the open. Subsequently, the robot places the baskets
baskets are securely placed in the boxes, they are onto the conveyor belts, which then undergo a visual
seamlessly transferred to the palletization process. inspection process. During the visual inspection, any
poor-quality baskets are identified and removed
SIMS 64 Västerås, Sweden, September 26-27, 2023

from the conveyor belt line to ensure product optimization, and overall improvement of industrial
quality. Moving on to Zone 2, this area is dedicated manufacturing processes.
to the packaging system, which is constructed along
the conveyor system. The packaging process begins 3.2. Decision Making
with an automated machine that prepares folded Creating a 3D simulation model for visualizing and
boxes. These prepared empty boxes are then optimizing industrial production processes
transported on the conveyor belt and stop near the necessitates a number of crucial decision-making
robot. With the box in place, the robot organizes the elements. The creation of discrete zones on the
baskets by picking and placing them in an organized production shopfloor gives an organized structure
sequential order within the box. Once the box is for analysing and improving each phase of the
filled, it is transported to another automated production line. The structure and arrangement of
machine, where it is sealed before being moved to the production shopfloor is the first key decision-
the next conveyor belt. making component. The shopfloor is divided into
Zone 3 represents the palletization process which particular zones, such as Zone 1, Zone 2, Zone 3, and
involves a conveyor system. In this zone, the boxes Zone 4, allowing for a systematic approach to
filled with baskets are placed on pallets with the understanding and optimizing the many functional
assistance of a robot. Once the pallets are filled with procedures involved. Choosing the best combination
the boxes, the conveyor system transports them to an of resources, machinery, and equipment for each
automated plastic wrapping station. At this station, zone is a critical choice that affects the overall
the pallets undergo a plastic wrapping process, efficiency and productivity of the production line.
ensuring their stability and protection during Decisions about the arrangement of injection
transportation and storage. After the plastic moulding machines, the overhead robot, and the
wrapping is complete, the pallets are transferred conveyor transport system were made within Zone
through the conveyor line to an automated pallet 1. To ensure seamless operation and efficient
stacking machine. This machine lifts the pallets and material flow, factors such as machine capacity,
stacks them on top of one another, optimizing space cycle times, and coordination between machines and
utilization and facilitating efficient storage. Finally, robots were taken into consideration. Moving on to
Zone 4 is dedicated to the storage of the pallets in Zone 2, the decision-making process constituted of
the warehouse. An automated stacker crane system creating an efficient packaging system along the
is employed in this zone to hoist the pallets and conveyor system. Choosing the right automated
arrange them in an organized manner. The design of machine for folding boxes, deciding the positioning
the stacker crane system ensures that the warehouse and sequencing of baskets by the robot, and ensuring
storage racks are within the crane's reach, enabling effective box sealing are all important factors that
seamless storage operations. affect the overall packing process. Decisions in Zone
As a result, the simulation model described here 3 revolve around the palletization process. The
provides a comprehensive picture of an industrial selection and location of the robot for palletizing the
automation case in the manufacturing industry. The boxes, optimizing the conveyor system for efficient
simulation model provides a full portrayal of the box transfer, and constructing the plastic wrapping
industrial production processes involved in making station to ensure secure and stable pallets for transit
plastic injection-moulded baskets by dividing the and storage are all important considerations. Finally,
production shopfloor into discrete zones and adding in Zone 4, the decision-making process revolves
various components and processes. The 3D around pallet storage in the warehouse. Choosing the
simulation software's representation of the right automated stacker crane system, customizing
production shopfloor allows for a clear knowledge the crane's reach and movement, and correctly
of the interconnection and operation of each zone. organizing the storage racks are all critical decisions
This visualization helps in the identification of in order to maximize space utilization and
potential bottlenecks, areas for improvement, and streamline storage operations.
the overall optimization of production efficiency, It is essential to examine elements such as system
quality, and profitability. The simulation model throughput, resource usage, material flow
demonstrates the importance of visualization and optimization, and overall production efficiency
simulation approaches in improving decision- throughout the decision-making process. Simulation
making in industrial manufacturing processes. modelling provides for the testing of numerous
Decision-makers can analyze the impact of many scenarios, the evaluation of the impact of various
aspects on the production line, such as throughput, choice alternatives, and the identification of
resource usage, and system performance, by potential bottlenecks or areas for improvement.
modeling the different zones. This enables educated
decision-making, which leads to better planning,
SIMS 64 Västerås, Sweden, September 26-27, 2023

3.3. Simulation Results the simulated industrial production system. These

findings can guide decision-making processes to
During the simulation, a total run time of 8 hours enhance the overall performance and productivity of
was chosen to align with the duration of a typical the production processes.
daily shift in the industrial production environment. The simulation model incorporates various process
This time frame allows for a comprehensive nodes that are programmed to operate within
evaluation of the production processes and the specific flow groups. In this particular simulation,
performance of the simulation model. In the there is a single flow group representing the
simulation model, three robots were strategically production of a specific product type, which in this
positioned at the junctions between the zones to case is baskets. Each process node within the model
facilitate the smooth transfer of baskets and optimize has the capability to assume different statistical
the overall material flow. process states, including idle, busy, and blocked.
The first robot, Robot 1, was placed overhead, To establish the interconnection between different
directly above the two injection-moulding machines zones, four process nodes were selected in this
in Zone 1. This robot plays a crucial role in picking simulation model. These process nodes serve as the
up the moulded baskets from the machines and critical links between the zones and play a crucial
transferring them to the conveyor belts. Robot 2 was role in the overall flow of the production process.
positioned between Zone 1 and Zone 2, acting as a Figure 7 visually represents the state results obtained
key component in the transition from the injection from these zonal process nodes. The results are
moulding process to the packaging system. It assists presented as percentages, reflecting the distribution
in organizing the baskets and placing them in the of different process states throughout the entire
boxes in a sequential order. Similarly, Robot 3 was production or simulation run time, which was set to
placed between Zone 2 and Zone 3, facilitating the 8 hours in this case.
movement of the filled boxes from the packaging
system to the palletization process. This robot plays
a vital role in placing the boxes on pallets, ensuring
efficient palletization. Figure 6 provides valuable
insights into the utilization of these three robots
throughout the 8-hour simulation run. The
utilization is represented as a percentage, indicating
the proportion of time each robot was actively
engaged in performing its designated tasks.

Figure 7: Idle, busy, and blocked States

Starting with the Zone 1 state process node, it
represents the initial stage where the baskets arriving
on the conveyor belt are picked up by Robot 2 and
subsequently placed in the Zone 2 (Packaging)
process node according to the programmed
assembly sequence. The Zone 2 (Packed Boxes)
Figure 6: Robot percentage utilization
process node captures the state of the final packed
These presented results allow for a deeper boxes. Here, Robot 3 is responsible for lifting the
understanding of the robots' workload distribution packed boxes and placing them onto the pallet,
and their efficiency in supporting the production which is represented by the Zone 3 (Palletization)
processes. By evaluating the utilization percentages, process node. Robot 3 follows a specific assembly
it becomes possible to identify potential bottlenecks sequence while arranging the boxes on the pallet. It
or areas of improvement within the production line. is noteworthy that each pallet accommodates a total
For instance, if a robot's utilization is consistently of 8 boxes, organized in a 2x2x2 stack configuration.
high, it may indicate a need for additional resources
By analysing the state results from these zonal
or process optimization to alleviate the workload.
process nodes, it becomes possible to gain insights
On the other hand, low utilization may suggest
into the efficiency and performance of the
under-utilized capacity that can be optimized for
production process. The percentages offer a
increased productivity. The utilization analysis of
quantitative assessment of the process states,
the robots provides valuable insights into the
indicating the proportion of time spent in each state
operational efficiency and resource allocation within
throughout the 8-hour simulation run. These results
SIMS 64 Västerås, Sweden, September 26-27, 2023

enable the identification of potential bottlenecks,

areas of improvement, or process optimization Therefore, to answer the research question, the use
opportunities within the production flow. of 3D simulation software and virtual reality (VR) in
4. Analysis and Discussion visualizing industrial production processes provides
useful insights to decision-makers for optimizing
The simulation model focuses on improving production efficiency. It enables informed decision-
decision-making in industrial production processes, making by providing a comprehensive picture of the
in the context of plastic injection-moulded basket production flow, resource utilization, and system
manufacturing. The simulation model provides a performance.
visual representation of the production shopfloor,
encompassing various related components and Decision-makers can increase the overall efficiency
processes, using 3D simulation software Visual and profitability of manufacturing processes by
Components®. This was further tested in Virtual identifying areas for improvement and resolving
Reality (VR) environment (Figure 8) to analyse the potential bottlenecks. The validation of the
simulation model and to initiate the decision-making simulation model was done during the development
process within the different zones which are phase through the immediate testing of simulation
representing different stages of the production line. animation results in the 3D world environment
The simulation model's decision-making process within the software. This validation was in the form
included identifying the structure and layout of the of correlating and checking if the flow components
production shopfloor, selecting the necessary were in accordance to the set requirements.
resources and equipment for each zone, and
optimising aspects such as material flow and system 5. Conclusion
throughput. Additional VR analysis enabled the
process of deciding how much space to be available In conclusion, this study highlighted the significance
so that operators can use it for maintenance. of 3D simulation modelling and visualization
techniques in improving decision-making and
optimizing production efficiency in industrial
manufacturing processes, with a specific focus on
plastic injection-moulded basket manufacturing.
The utilization of 3D simulation software, coupled
with VR testing, allowed for a comprehensive and
immersive representation of the production
shopfloor, showcasing interconnected components
and processes.

Decision-makers can examine and comprehend the

production flow, resource allocation, and system
performance with the help of the simulation model.
Additionally, the developed model is flexible in
Figure 8: Simulation model testing in VR order to accommodate future modifications. By
examining the utilization of robots in different
Simulation results show the utilization of robots zones, potential areas for improvement can be
positioned in different zones, allowing for the identified, leading to enhanced resource utilization
identification of potential areas for improvement. It and increased production efficiency. The analysis of
was observed from the robot utilization chart (Figure process states within the zones further contributes to
6), that the utilization percentage for Robot 2 was identifying bottlenecks and optimization
less and Robot 3 was much lesser. This tells us that opportunities within the production process.
there is a possibility for further expanding Zone 1
with more injection-moulding machines. The By offering visual context, dynamic interaction, and
analysis of process states within the zones provided the capacity to test possibilities, 3D simulations and
insights into the efficiency and performance of the VR technologies transform shopfloor decision-
production process. Similarly, it was also observed making. They uncover complicated relationships,
in Zones 1 and 2, the idle time amounted to more possible bottlenecks, and ergonomic difficulties that
than 90% of the total simulation run time. Because statistics overlook. These systems detect problems
of this, it is possible to advise the business early, improve communication, and provide a visual
management that the current process will be able to knowledge of shopfloor processes. They alter
support any future investments in additional structure, throughput, and efficiency decisions by
injection moulding machines in the case concerning displaying the shopfloor layout, equipment, and
increasing the production capacity. processes. Unlike traditional numerical analysis, 3D
SIMS 64 Västerås, Sweden, September 26-27, 2023

simulations and VR provide decision-makers with

immersive insights, allowing them to make educated
decisions that lead to optimised industrial
production processes. The findings from the
simulation model and visualization techniques
demonstrate the importance of informed decision-
making in industrial manufacturing. Decision-
makers can leverage the insights gained from the
simulation model to make educated decisions
regarding the structure and arrangement of the
production shopfloor, selection of appropriate
resources and equipment, and optimization of
material flow and system throughput.

Acknowledgment

I would like to thank MITC AB, Eskilstuna for

providing me with the resources which were
valuable for conducting this research.

References
Abidi, M.-A., Chevaillier, P., Lyonnet, B., Kechiche, M., Baert,
P., & Toscano, R. (2020). How to Create a New Generation of
Industrial Processes Simulation by Coupling Simulation Tools
with VR Platforms.

Atmakuri, S., Upadhya, G., Wang, C. M., Chandra, U., & Paul,
A. J. (1993). The role of visualization in process simulation. JOM,
45(10), 21–24. https://doi.org/10.1007/BF03222455

Chawla, R., & Banerjee, A. (2001). A virtual environment for

simulating manufacturing operations in 3D. Proceeding of the
2001 Winter Simulation Conference (Cat. No.01CH37304), 2,
991–997. https://doi.org/10.1109/WSC.2001.977404

Garcia-Crespo, A., Ruiz-Mezcua, B., Lopez-Cuadrado, J. L., &

Gomez-Berbis, J. M. (2010). Conceptual model for semantic
representation of industrial manufacturing processes. Computers
in Industry, 61(7), 595–612.
https://doi.org/10.1016/j.compind.2010.01.004

Molenda, P., Jugenheimer, A., Haefner, C., Oechsle, O., & Karat,
R. (2019). Methodology for the visualization, analysis and
assessment of information processes in manufacturing
companies. Procedia CIRP, 84, 5–10.
https://doi.org/10.1016/j.procir.2019.04.291

Wang, J., Phillips, L., Wu, B., Moreland, J., & Zhou, C. (2015).
Simulation and Visualization of Industrial Processes in Unity.

Xu, T., Song, G., Yang, Y., Ge, P., & Tang, L. (2021).
Visualization and simulation of steel metallurgy processes.
International Journal of Minerals, Metallurgy and Materials,
28(8), 1387–1396. https://doi.org/10.1007/s12613-021-2283-5

Yang, T., Yi, X., Lu, S., Johansson, K. H., & Chai, T. (2021).
Intelligent Manufacturing for the Process Industry Driven by
Industrial Artificial Intelligence. Engineering, 7(9), 1224–1230.
https://doi.org/10.1016/j.eng.2021.04.023