{"id":11796,"date":"2025-12-18T10:39:15","date_gmt":"2025-12-18T15:39:15","guid":{"rendered":"https:\/\/blogs.sw.siemens.com\/tecnomatix\/?p=11796"},"modified":"2026-03-26T07:11:26","modified_gmt":"2026-03-26T11:11:26","slug":"before-humanoids-hit-the-factory-floor-validating-humanoids-with-manufacturing-simulation","status":"publish","type":"post","link":"https:\/\/blogs.sw.siemens.com\/tecnomatix\/before-humanoids-hit-the-factory-floor-validating-humanoids-with-manufacturing-simulation\/","title":{"rendered":"Before Humanoids Hit the Factory Floor: Validating the Future with Manufacturing Simulation"},"content":{"rendered":"\n

Market trends suggest that humanoids will have the potential to become a significant work source in the manufacturing space within the next few years, helping to combat the workforce shortage many companies are already facing. The promise of a robot that embodies both the intelligence and form factor of a human is exciting and it is widely stated that the critical development period for humanoids will continue over the next two to five years. In fact, a simple search of humanoid-related patents reveals thousands of filings, led by China, the United States, and Japan. Furthermore, a comprehensive Morgan Stanley<\/a> review noted that 73% of companies have confirmed their involvement with humanoids, reinforcing the momentum behind this technology.<\/p>\n\n\n

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Humanoid systems are inherently complex, requiring substantial investment not only in physical hardware but also in intelligence, the \u201cbrain\u201d of the robot. Expertise in sensors, control systems, machine learning, AI, and natural language interaction are all essential to humanoid development. Just as importantly, deploying humanoids requires a deep understanding of their capabilities and limitations, much like how manufacturers today must carefully assess what humans and traditional industrial robots can \u2014 and cannot \u2014 do effectively.<\/p>\n\n\n\n

At Siemens, this understanding is built through high-fidelity simulation. Using tools such as Tecnomatix Process Simulate, Siemens software enables manufacturers to precisely model how manufacturing labor resources respond to task requirements. With strong competencies in advanced robotics and human simulation, Siemens solutions are uniquely positioned to model flexible manufacturing environments that blend automation, human workers, and emerging humanoid systems.<\/p>\n\n\n\n

Meet the authors:<\/h3>\n\n\n\n
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Christina Cort, Product Owner, Human Simulation Technologies, Siemens Digital Industries Software<\/figcaption><\/figure>\n\n\n\n
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Alex Greenberg, Director Advanced Robotics Simulation Program, Siemens Digital Industries Software<\/figcaption><\/figure>\n<\/figure>\n\n\n\n

Siemens investment in humanoid and Autonomous Systems Research<\/h3>\n\n\n\n

Siemens leadership in this space extends well beyond software. At the research level, Siemens is actively investing in the foundations of humanoid and autonomous robotics through its Foundational Technologies organization. One example is Dr. Georg von Wichert<\/a>, who heads the Autonomous Systems & Control research group at Siemens Foundational Technologies in Garching, Germany.<\/p>\n\n\n

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An example of contact-competent hardware\/control for safe human-humanoid interaction (with TUM humanoid robot, H1)<\/em><\/figcaption><\/figure><\/div>\n\n\n

His work focuses on cognitive systems, sensor data fusion, autonomous machines, and the critical challenge of translating fundamental research into industrial reality, precisely the gap that humanoids must cross to become viable manufacturing resources.<\/p>\n\n\n\n

In his recent thought leadership on bridging the gap between simulation and reality<\/a>, Dr. von Wichert emphasizes that physical experimentation alone is too slow and too costly for modern robotics development. Training data is often scarce, and real-world testing carries safety and reliability risks. Robotics simulation<\/a>, by contrast, enables engineers to prototype behaviors, validate designs, and explore \u201cwhat-if\u201d scenarios in a virtual environment before deploying a real robot. This approach accelerates iteration, improves repeatability, and significantly reduces risk.<\/p>\n\n\n\n

This is where Siemens Software plays a direct role where Dr. von Wichert explicitly references Process Simulate<\/a> as a key enabler for bridging simulation and reality, reinforcing the close partnership between Siemens research teams and its industrial software portfolio. The result is a continuous feedback loop between research, simulation, and deployment, a critical requirement for humanoids to transition from experimentation to production. Explore how Process Simulate <\/a>could be a critical solution for de-risking the integration of humanoids into modern manufacturing in the demonstration below.<\/p>\n\n\n\n

Towards human-centric and general-purpose robotics<\/h3>\n\n\n\n

Achieving general-purpose humanoid capability requires more than precise motion planning. Robots must be able to recognize human intent, communicate naturally, and operate safely during purposeful contact, especially in environments such as factories, homes, and healthcare facilities.<\/p>\n\n\n

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Dexterous and adaptive control of Unitree G1 Humanoid with Physical AI<\/em><\/figcaption><\/figure><\/div>\n\n\n

Today\u2019s humanoids still lack a robust mid-layer between high-level reasoning and low-level control. Robots can plan tasks and stabilize motions, but they struggle to translate intent into adaptable, reliable skills under real-world variability. While robot-native foundation models and advanced control approaches are emerging, they are not yet mature. Until then, specialized automation remains the most effective solution for tightly constrained tasks, while humanoids make the most sense in human-designed, variable, or hazardous environments.<\/p>\n\n\n\n

Manufacturing simulation as the foundation for humanoid integration<\/h3>\n\n\n
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Simulate and validate humanoids in Process Simulate software<\/em><\/figcaption><\/figure><\/div>\n\n\n

Today, Siemens leads the charge in manufacturing simulation technologies, now with a clear eye on the humanoid future. While the potential of humanoids is undeniable, manufacturers must still answer fundamental questions about where, when, and how to deploy them effectively. <\/p>\n\n\n\n

This is precisely where Siemens Process Simulate becomes indispensable<\/a>. Manufacturers are excited by how quickly humanoid systems can learn and evolve, but that same adaptability introduces new layers of unpredictability. Process Simulate enables teams to create a comprehensive digital twin<\/a> of the production environment, including people, robots, automated equipment, and eventually humanoids, within a single, unified virtual space. Engineers can identify integration issues early, verify feasibility, refine processes, avoid resource conflicts, and validate cycle times long before anything is installed on the factory floor.<\/p>\n\n\n\n

With Process Simulate<\/a>, manufacturers can evaluate critical variables such as:<\/p>\n\n\n\n