{"id":11485,"date":"2025-07-25T11:30:02","date_gmt":"2025-07-25T15:30:02","guid":{"rendered":"https:\/\/blogs.sw.siemens.com\/tecnomatix\/?p=11485"},"modified":"2026-03-26T07:10:54","modified_gmt":"2026-03-26T11:10:54","slug":"simulation-without-limits-bringing-ai-digital-twin-and-copilots-to-the-factory-floor","status":"publish","type":"post","link":"https:\/\/blogs.sw.siemens.com\/tecnomatix\/simulation-without-limits-bringing-ai-digital-twin-and-copilots-to-the-factory-floor\/","title":{"rendered":"Simulation without limits: bringing AI, Digital Twin, and Copilots to the Factory Floor\u00a0"},"content":{"rendered":"\n

Today, manufacturing simulation is being reimagined \u2013 thanks to AI-powered copilots, low-code interfaces, and seamless connectivity to real production data. Simulation is increasingly being used by more people, more often, and at more points in the manufacturing lifecycle. <\/p>\n\n\n\n

Manufacturers are being pushed to do more with less \u2014 reduce downtime, cut energy costs, improve productivity, and empower a workforce in flux. The key to doing all this efficiently? That\u2019s where AI-powered simulation and digital twin technology is helping boost manufacturer\u2019s transformation faster than ever before.  <\/p>\n\n\n

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Uli Rossgoderer<\/strong> 
Senior Director Portfolio Development<\/strong> 
Siemens Digital Industries Software<\/strong> <\/figcaption><\/figure><\/div>\n\n\n

In a recent webinar hosted by leading industry publication Automation World<\/a>, Uli Rossgoderer<\/strong>, Senior Director of Portfolio Development for the Tecnomatix portfolio, joined the discussion to discuss how manufacturing simulation technologies are becoming more intelligent, accessible, and impactful across the manufacturing floor. <\/p>\n\n\n\n

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Watch the webinar<\/strong> <\/a><\/div>\n<\/div>\n\n\n\n

Here’s a closer look at the key insights \u2014 and why you should watch the full session:<\/h1>\n\n\n\n

The big shift in modern manufacturing <\/strong> <\/h2>\n\n\n\n

Modern manufacturing is undergoing a major transformation. With AI copilots, cloud-powered low-code interfaces, and real-time data integration, simulation is no longer limited to experts. Manufacturers can now optimize processes faster, with fewer resources, and empower a broader range of users \u2014 even those without deep technical expertise. <\/p>\n\n\n

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As Uli explained, Siemens isn\u2019t just enhancing simulation tools \u2014 it\u2019s democratizing them. AI-powered interfaces are making complex capabilities more accessible and intuitive, enabling more teams to drive value from simulation, whether in robotics, production planning, discrete event modeling, or ergonomic analysis. <\/p>\n\n\n\n

Robotic Simulation<\/strong> <\/h2>\n\n\n\n

Another area seeing massive transformation is robotics simulation<\/strong>. Siemens is making these once-complex tools more approachable, even for smaller manufacturers. <\/p>\n\n\n\n

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\u201cWe\u2019re making robotic simulation more accessible. With software-as-a-service and simplified interfaces, even small manufacturers can simulate robotic cells without disrupting production.\u201d<\/em><\/p>\n<\/blockquote>\n\n\n\n

Simulation Copilots: Smarter, Not Harder<\/strong> <\/h2>\n\n\n\n

A major enabler of this shift is Siemens investment in AI copilots<\/strong><\/a> for simulation. These copilots assist users in generating simulation logic, interpreting results, and even suggesting actions \u2014 all through natural language interfaces. Readily available in Process Simulate, the Copilot plays a critical role in minimizing production downtime with advanced AI-powered troubleshooting. Imagine instantly diagnosing issues in complex robotic simulations\u2014without manual effort. By delivering fast, automated debugging, Copilot transforms problem-solving into an intuitive, precise process. And it doesn\u2019t stop at detection\u2014it recommends practical solutions, such as optimizing robot cycle times, empowering engineers to accelerate production and improve overall efficiency. <\/p>\n\n\n

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Uli also touches on the development plans for Plant Simulation and SimTalk and what this means for users. For example, we\u2019re making it simpler for SimTalk novice users. Simply describe the process you want to simulate: \u201cModel a buffer with limited capacity,\u201d or \u201cAdd a shift schedule to this station\u201d\u2014and the Copilot is there to help. It leverages documentation sources to suggest lines of codes and going forward will help to suggest improvements. <\/p>\n\n\n\n

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For example, in Plant Simulation, we want it to make easier for users to use SimTalk. They just describe what they want to simulate \u2014 and the copilot helps generate the model or fix errors,\u201d says Uli.<\/em><\/p>\n<\/blockquote>\n\n\n\n

Whether you\u2019re troubleshooting a simulation or building a factory model from scratch, the Copilot turns natural language into executable logic \u2014 accelerating development, reducing errors, and opening simulation to a broader range of users. <\/p>\n\n\n

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Ergonomics Simulation: Insights from a Simple Photo Upload<\/strong> <\/h2>\n\n\n\n

Another area where AI-powered simulation is making waves is in ergonomics<\/strong>. Uli shared how Siemens is simplifying workplace safety assessments<\/a> using AI-powered ergonomic analysis: <\/p>\n\n\n\n

\u201cUsers can upload a photo of a worker at a station. Our simulation powered with AI matches it to a virtual model and runs a full ergonomic assessment \u2014 instantly flagging risk factors.\u201d<\/em> <\/p>\n\n\n\n

Breaking Down Barriers to Scale and Cloud-Based Simulation <\/strong> <\/h2>\n\n\n\n

While engineers thrive with complex models, shift leaders and production managers need something more intuitive. Uli pointed to Optimize My Plant<\/strong><\/a>, a Siemens application that wraps simulation models in a low-code user interface<\/strong>, enabling line managers to run \u201cwhat-if\u201d scenarios independently. Optimize my plant<\/strong> solves this with a user-friendly interface that provides real-time KPIs, enabling all levels of the organization to act on data rather than gut feel. <\/p>\n\n\n\n

\u201cWe\u2019re bringing simulation closer to daily operations. This lets non-experts interact with complex models and make smarter decisions \u2014 without calling in a simulation expert every time.\u201d<\/em> <\/p>\n\n\n

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What\u2019s Next? Autonomous AI & Human-Robot<\/strong> Interaction<\/strong><\/h2>\n\n\n\n

Looking ahead, Uli predicts major leaps in autonomous AI agents<\/strong>, humanoids, robot integration, and simulation-guided decision-making. <\/p>\n\n\n\n

\u201cThe next step is not just generating insights, but taking action. Copilots will suggest changes \u2014 and eventually implement them.\u201d<\/em> <\/strong><\/p>\n\n\n\n

He also pointed to the growing role of situational awareness for robotics<\/strong> \u2014 where robots use simulation and AI to make decisions in real time, based on camera input or environmental sensors. <\/p>\n\n\n\n

These highlights just scratch the surface. In the full session, Uli explores: <\/p>\n\n\n\n