Simulation
Optimise Your Production and Logistics Operations with Simulation
AFRY is a leading provider of Simulation and Digital Twin solutions, supporting manufacturers, warehouses, and logistics operations in designing, validating and optimising complex systems virtually. Simulations empower confident and data-driven decision-making, reducing risk, accelerating time to market, and unlocking operational efficiency. From strategic consulting to advanced implementation, AFRY provides end-to-end support tailored to your unique challenges. Our strength lies not only in scale and expertise, but in our proven track record across industries—helping clients succeed in high-stakes environments where precision and performance matter most.
What is Simulation?
In this context, Simulation refers to Discrete Event Simulation (DES), a computer-based method for modelling, analysing, visualising, and optimising complex, time- and resource-dependent systems. Also known as material flow simulation or process simulation, DES goes beyond static tools such as Excel spreadsheets, VBA, or linear programming by capturing dynamic interactions and time-critical events, including queues, bottlenecks, fluctuations, and downtime.
By experimenting in a safe virtual environment, organisations can explore “what-if” scenarios without disrupting live operations or committing to costly investments too early.
Simulation creates a Digital Twin of operations where teams can:
- Develop, test, and refine process designs, layouts, planning principles, and control logics.
- Evaluate performance across different scenarios and assumptions.
- Identify risks, inefficiencies, and opportunities for improvement.
- Support fact-based decisions that reduce risk, accelerate timelines, and enable smarter investments.
In short, simulation transforms complexity into clarity—turning dynamic systems into actionable insights.
Turning Complexity into Business Value
Simulation is more than just a technical tool. It is a strategic enabler that helps organisations make smarter, faster and more reliable decisions. By creating a virtual environment for testing ideas, validating assumptions, and optimising solutions, simulation reduces uncertainty and maximises return on investment. Whether in early planning, detailed design, or daily operations, simulation provides the clarity and confidence needed to drive performance, reduce risk, and unlock new opportunities.
Business Value of Simulation
- De-risk investments – Validate capacity, flows, staffing levels, and control strategies before committing capital.
- Faster, better decisions – Compare scenarios with clear KPIs and visual models that align stakeholders.
- Cost and time savings – Explore alternatives virtually to avoid costly redesigns, delays, and startup issues.
- Operational optimisation – Identify bottlenecks, inefficiencies, and opportunities for continuous improvement.
- Improved collaboration – Create a shared, transparent view across disciplines and functions.
- Scalability and flexibility – Adjust model scope and detail to fit different project phases, from feasibility to operations.
- Safe experimentation – Test “what-if” scenarios in a risk-free environment before making changes in reality.
Why AFRY
With a large, dedicated team, complemented by a strong global partner network, AFRY deliver full-spectrum simulation support, covering everything from strategic consulting to advanced modelling and implementation. Our strength lies not only in scale and expertise, but also in the proven experience of both successful and challenging projects, giving us the insight needed to help our clients succeed where it matters most.
Methods and tools for a full spectrum simulation support
- 1. Modelling and analysis projects
- 2. Develop client specific simulation tools and user interfaces
- 3. Pilots and case studies
- 4. Standardized work method
- 5. Modeling methodology
- 6. Software support
- 7. Expert consultation
- 8. Specialist for hire
AFRY supports customers with simulation modelling and analysis projects to ensure well-calculated, risk-mitigated and high-quality decisions, all resulting in thoroughly validated system designs. We guide clients through the entire process from needs assessment and defining key questions, to analysis and actionable results. By integrating simulation into the core of design and engineering, we enable continuous improvement, smarter investments, improved performance and efficiency, as well as increased robustness and reliability.
AFRY helps customers streamline operations with tailor-made simulation tools and easy-to-use interfaces. These tools allow even non-experts to perform their own analyses with confidence. Together with the client, we define the necessary functionalities, build the model and userinterface, support license acquisition, and provide training on experiment planning, analysis, and result interpretation.
For customers new to simulation, AFRY offers pilot studies and case projects to demonstrate the value of simulation in practice. While limited in scope, they help clients build competence, gain hands-on experience, and identify opportunities for future simulation use. Often conducted as thesis work with selected students under AFRY’s guidance, these pilots provide valuable insights into processes and applications.
AFRY advises customers in building simulation capability within their organization. This includes defining roles, establishing processes, and implementing standards for quality-assured projects. With the right structure in place, simulation becomes an integral and reliable tool for design, development, and decision-making.
AFRY offers training in simulation methodology, providing participants with a structured framework to manage projects effectively. The program is software-independent and covers key areas such as scoping, modelling approaches, experiment planning and results analysis.
AFRY provides expert guidance in choosing the simulation software that best fits your organization’s needs. Through tailored training, we help teams quickly build competence and unlock value from the chosen platform.
AFRY’s senior experts bring unique strategic insight to simulation projects, from scoping and defining purpose to setting an appropriate level of detail and data requirements. They ensure simulation is applied at the right time, with the right methodology and tools, to maximise value. This includes advice on software selection, data structure, and procurement strategies—making sure simulation supports critical project decisions.
AFRY provides skilled simulation specialists on demand, helping organizations handle peak workloads or temporary needs for advanced expertise.
Key Drivers for Successful Simulation
Curious to learn what drives successful simulation?
Click the arrow to explore the five key drivers that make simulation projects truly impactful.
Purpose
The simulation requires a clearly defined purpose that establishes a shared understanding of the project goals and which KPIs the project aims to deliver. This purpose guides the selection of processes to include in the model and determines the required level of detail.
Process Knowledge
To accurately replicate processes in the simulation models, detailed process design and knowledge are essential. This includes understanding specific process characteristics and how processes interact and depend on each other.
Data
To achieve the desired level of detail in simulation modelling, relevant and well-structured data is required. This includes product and process characteristics and higher-level data such as market demand, production plans and schedules. Simulations can be based on historical data when available, and with experience-based and fabricated data when needed.
Simulation Competence
Simulation competence requires both skilled project managers and dedicated specialists. Project managers define strategy, select tools, and ensure alignment with goals. Specialists bring software expertise and build the core model— together enabling effective, high-quality simulation projects.
Documentation
Well-structured documentation ensures quality and transparency in simulation projects. It builds shared understanding early, captures key assumptions and decisions, and supports future reviews if conditions change—making it easier to trace, justify, and adapt design choices throughout the project.
Software & Methodology – Flexible Tools, Structured Results
At AFRY, we are both software-agnostic and methodology-driven. We work seamlessly across leading Discrete Event Simulation platforms such as Siemens Plant Simulation, FlexSim, AutoMod, and Visual Components, always choosing the tool that best matches the project scope, client preferences, and system requirements. Our clients never need to adapt their needs to fit a tool. We adapt the tool to fit their needs.
But software alone is not what makes simulation successful. The real value lies in how models are designed, scoped, and validated. That’s why methodology is at the core of everything we do. We combine proven engineering practices with agile ways of working, supported by modern tools for software management and version control. This ensures quality, traceability, and efficiency throughout the project lifecycle.
Together, our flexible software choices and structured methodology transform simulation into powerful decision support - reducing risk, shortening timelines, and delivering insights that unlock measurable business value.
More about Digital Twin and it’s siblings
Not all Digital Twins are the same. Simulation (DES) is one type of Digital Twin, but only one among several related approaches. While all Digital Twins share the goal of mirroring and understanding complex systems, they differ in methodology, level of detail, and intended purpose.
At AFRY, we help you navigate these differences and apply the right type of Digital Twin at the right phase of your project. Whether the objective is to validate early concepts, integrate and test control systems, or optimize daily operations, we ensure the approach matches the challenge.
The real power of Digital Twins lies in their ability to deliver predictive insights, enable safe experimentation, and support fact-based decisions—long before physical changes are made.
Every Digital Twin has its role, but it’s normally with Simulation where smart design decisions begin.
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