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Process Simulate

Process Simulate is a digital manufacturing solution for manufacturing process verification in a 3D environment. Process Simulate is a major enabler of speed-to-market by allowing manufacturing organizations to virtually validate manufacturing concepts upfront – throughout the lifecycle of new product introductions. The ability to leverage 3D data of products and resources facilitates virtual validation, optimization and commissioning of complex manufacturing processes, resulting in faster launch and higher production quality.

The increased complexity of products and manufacturing processes presents world-class manufacturers with “time-to-market” and asset optimization challenges. Manufacturing engineering teams are expected to enable flawless new product launches and adhere to cost, quality and start of production targets. To meet these challenges, leading manufacturers leverage their organizational knowledge and the availability of 3D models of products and resources to virtually validate their manufacturing processes upfront. With new evolving technology, thousands of validation experiments can be conducted efficiently and almost automatically to ensure upfront production optimization. Process Simulate facilitates the design and validation of manufacturing processes in a 3D dynamic environment. Process Simulate is fully integrated with the manufacturing backbone, thus enabling manufacturing engineers to reuse, author and validate manufacturing processes. Process Simulate provides an advanced 3D environment capable of emulating realistic behavior of manufacturing processes and optimization of cycle times and process sequence. Process Simulate facilitates simulation of assembly processes, human operations and mechanical procedures of tools, devices and robots. Process Simulate is highly scalable, providing various engineering disciplines with the data and toolset to examine detailed processes and verify them in different phases and perspectives.

Process Simulate Robotics

PMC has been using Process Simulate Human & Robotics since 2004. Besides performing detailed simulations, PMC can provide training to meet your simulation requirements.

Process Simulate Robotics

Examples of Process Simulate robotic deliverables are:

  • Robot Loading / Unloading of product in a station and/or tool
  • Robot consumption and allocation of joining features to a process (Weldpoints, Adhesive, Rivets, etc.)
  • Robot reach studies
  • Robot collision detection for product and tooling
  • Cycle time analysis
  • Material flow studies
  • Assembly validation analysis
  • Robot utilization
  • Robot programming
  • Enhanced robot I/O behavior
  • Virtual Commissioning
Process Simulate Human

Process Simulate Human

Utilizing the Human feature inside Process Simulate, PMC has been performing ergonomic and lean manufacturing studies since 2013 for the automotive, aerospace and shipyard industries. Besides performing detailed simulations, PMC can provide training to meet your simulation requirements.

Examples of Process Simulate human deliverables are:

  • Human Loading / Unloading of product in a station and/or tool
  • Human consumption and allocation of joining features to a process (Weldpoints, Adhesive, Rivets, etc.)
  • Human reach studies
  • Human collision detection for product and tooling
  • Human cycle time analysis
  • Material flow studies
  • Human walk distance studies
  • Assembly validation analysis
  • Human utilization
  • Plus human reporting tools for; Static Strength Predictions, Force Solver Analysis, Fatigue & Recovery Analysis, Lower Back Spinal Force Analysis, Lifting and Posture Analysis, Cumulative Back Loading Analysis and Metabolic Energy Expenditure Analysis


  • Reduce cost of change with early detection and communication of product design issues
  • Reduce number of physical prototypes with upfront virtual validation
  • Optimize cycle times through simulation
  • Ensure ergonomically safe processes
  • Reduce cost by re-using standard tools and facilities
  • Minimize productions risk by simulating several manufacturing scenarios
  • Early validation of the mechanical and electrical integrated production processes (PLC and robotics)
  • Early validation of production commissioning in a virtual environment
  • Increase process quality by emulating realistic processes throughout the process lifecycle


  • 3D simulation
  • Static and dynamic collision detection
  • 2D and 3D sections
  • 3D measurements
  • Sequencing of operations
  • Assembly and robotic path planning
  • Resource modeling (3D and kinematics)
  • Line and workstations design
  • Documentation tools
  • Natively supported JT™ visualization standard
  • Human tasks simulation
  • Reach envelopes
  • Vision window
  • Postures
  • Auto grasp wizard
  • Ergonomics analysis
  • Discrete and continuous process simulation
  • Projection of welds on parts
  • Gun search wizard
  • Project arc seam
  • Torch alignment
  • Weld gun validation
  • Design/modify weld gun and tooling geometry and kinematics
  • Robot reach test
  • Robot smart placement
  • Robotic simulation editing
  • Robotics process simulation
  • Event-driven simulation
  • Detailed robot programming
  • Controller-specific command recognition
  • Boolean and non-Boolean signals exchange
  • Robot logic editing and validation
  • Virtual commissioning
  • Model control resources (sensors and controlled devices)
  • Signal definition based on real HW
  • Simulate internal resource logic (Boolean and analog)
  • Connect virtual model with real PLC code
  • Integrated simulation using actual PLC code and HW over OPC interface

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