Simulation and emulation transform the manufacturing landscape by reducing risk, increasing efficiency, and enabling innovative solutions. Mark Venables met with Nicola Iovine, Business Development Manager EMEA, Rockwell Automation, to explore the evolving role of these technologies and how they are shaping the future of production.
In the rapidly evolving manufacturing landscape, staying competitive means more than just optimising costs or increasing output; it is about predicting outcomes, mitigating risks, and continuously improving efficiency. With shorter product lifecycles, rising complexity in production processes, and growing pressure to adopt Industry 4.0 technologies, manufacturers are seeking smarter ways to plan and execute their operations. This is where simulation and emulation come into play.
The differences between simulation and emulation
“There is always a lot of confusion in the market when we talk about simulation and emulation,” Nicola Iovine, Business Development Manager EMEA, Rockwell Automation, begins. “Simulation is about running experiments on different types of equipment, which could be an entire line or a single machine. But when simulating, we do not need to add any physical properties to the assets; they could just be simple 2D assets, and we can use them to run offline experiments.”
Therefore, simulation is not interested in the exact physical behaviour of the machinery. Instead, it is focused on broad operational questions, such as determining a system’s capacity or identifying potential bottlenecks during early feasibility studies. “It is about the bigger picture,” Iovine continues. You want to know how much material can be processed, what the capacity is, or how potential changes affect system throughput.”
Simulation is essential during the initial design stages of a project. It allows manufacturers to experiment with different layouts, processes, and even production rates without the risk of physical changes. By modelling these scenarios, companies can make informed decisions that help them achieve optimal performance from the very beginning. This approach saves time and enables manufacturers to allocate resources more effectively, ensuring that the chosen configuration will be as efficient as possible once implemented. “With simulation, you can try out different what-if scenarios and optimise without touching the physical setup,” Iovine adds. “It is like having a laboratory for your production line, where every experiment is risk-free.”
Emulation, in contrast, is a far more detailed and realistic modelling process. “When we talk about emulation, we are talking about creating a much closer representation of the physical machine,” Iovine explains. “We put physical properties into the model to behave similarly to a real-world machine. This is especially useful when we want real-time connectivity, either with physical controllers or emulated controllers.” Emulation comes into play later in a project’s lifecycle when manufacturers approach the testing and validation phase. “By emulating the machine’s behaviour, we can validate its performance under real operating conditions,” Iovine adds. “It ensures everything works as expected before commissioning, reducing the risk of surprises once physical systems are in place.”
The value of emulation also extends into areas such as troubleshooting and operational efficiency. Using emulation, manufacturers can test software changes or new control algorithms on a digital model before applying them to the physical machine. This approach significantly minimises downtime and prevents production losses. “Imagine being able to test software updates virtually without worrying about halting the entire production line,” Iovine says. “Emulation gives you that peace of mind. It’s about being proactive rather than reactive.”
Emulate3d as an integrated solution
“When designing a new machine or adding new technology to an existing line, you want to test everything in the digital world first to see if it will meet your expectations,” Iovine explains. The value of an integrated simulation and emulation platform becomes even more evident when considering manufacturers’ unique challenges. The need to reduce downtime, minimise risk, and optimise production is stronger than ever.
Emulate3D provides a unique opportunity to evaluate how different systems work together, both at the machine and plant levels, before any equipment is purchased or deployed. “What makes Emulate3D unique is that it combines both simulation and emulation capabilities in one platform,” Iovine continues. You can simulate or emulate anything from a single machine to an entire factory. It is flexible enough to handle whatever automation systems are in use, regardless of whether it is Rockwell technology or equipment from another vendor.”
This openness extends to integrating CAD packages, allowing customers to reuse existing CAD data to build digital models, and powerful scripting capabilities, which allow for further customisation. Manufacturers can also leverage Emulate3D for digital twins, which are increasingly used to create comprehensive digital versions of physical assets. A digital twin can represent an entire factory, making it possible to monitor and optimise the operation in real time. “The combination of simulation, emulation, and digital twins allows for a full understanding of both the design and operational phases,” Iovine explains. “It is a game changer regarding proactive management and optimisation.”
Emulate3D supports the introduction of new technologies into existing environments. For example, if a manufacturer is considering adding robots or automated guided vehicles (AGVs) to a production line, Emulate3D can simulate the impact of these changes on overall line efficiency. This helps ensure that new technologies are seamlessly integrated without disrupting current operations. “We see a lot of customers using Emulate3D to make strategic technology decisions before they spend a penny on physical hardware,” Iovine says.
Optimising existing lines and improving collaboration
Emulate3D also plays a crucial role in enhancing collaboration. With today’s highly distributed and complex supply chains, different teams, suppliers, and partners often need to work together to bring a project to life. Digital factory models allow for real-time collaboration across geographies.
“Different suppliers or engineers can work simultaneously on parts of the model, and then, at a certain point, all these components come together into one cohesive digital factory,” Iovine says. “This way, each engineer focuses on their specific component while still contributing to the overall model. It makes collaboration easier, faster, and far more efficient.”
This collaborative approach is central to building a truly integrated and resilient production system where every stakeholder can see their contribution within the broader context of the project. “Emulate3D’s ability to simulate and emulate at various levels, from a single machine to a full plant, means that everyone involved in the project has access to a comprehensive digital version of the production system,” Iovine continues. “This visibility is key for successful project execution, particularly when dealing with numerous contractors and equipment suppliers. We have seen how a well-executed digital model can eliminate stakeholder misunderstandings and ensure everyone is aligned before anything hits the factory floor.”
Some manufacturers are also using Emulate3D in real-time environments by creating what is called a digital shadow. “In some cases, customers have both the real machine and its digital twin running in parallel,” Iovine explains. “This way, they can cross-check real-time data against the digital model to identify discrepancies. If there is a deviation, it could signal an anomaly or indicate that something is going wrong on the line. Using the digital twin as a cross-checking tool helps detect issues early and provides valuable insights into machine behaviour, which can be used for predictive maintenance and future optimisations.”
Exploring the potential of AI
Looking ahead, Iovine sees AI playing an increasingly important role in the evolution of simulation and emulation technologies. “We are exploring how AI can be used to make the model-building process more efficient, particularly for repetitive tasks,” he says. “For example, in scenarios where you have long conveyor lines or repeated components, AI could assist in generating those models faster and with greater accuracy. AI can also help validate models in real-time, checking for discrepancies and suggesting modifications to improve system performance. We are working towards a point where digital twins can be used alongside physical machines in real-time, with AI monitoring for deviations and suggesting adjustments to maintain optimal operation.”
The potential of AI extends beyond simply accelerating model-building. Advanced AI algorithms can identify inefficiencies that may not be obvious to human engineers. By running simulations, AI can pinpoint the optimal configuration for a production line or suggest changes that lead to significant gains in productivity. “We are just scratching the surface of what AI can do when integrated with simulation and emulation,” Iovine notes. “Imagine a system that not only models production but actively helps you improve it by learning from data and iterating on designs.”
The integration of AI does not end there. Iovine also mentioned plans to leverage AI for other advanced applications, such as version control, particularly in regulated industries like pharmaceuticals. “With regulated industries, tracking changes is crucial,” he says. “Emulate3D can track changes to models, automation programs, and more, providing a clear history of modifications, which is incredibly important during validation. This capacity for detailed version control ensures manufacturers can navigate stringent compliance requirements more effectively, reducing the risk of regulatory setbacks.”
Emulate3D allows for efficient version control and provides a clear audit trail, ensuring that every change made to a model or production process is documented. This helps manufacturers demonstrate compliance and pass audits more efficiently, a critical capability for maintaining market access in these highly regulated sectors.
Simulation and emulation are no longer just tools for testing and validation; they are becoming central to the entire manufacturing lifecycle. From designing new systems and integrating advanced technologies to optimising existing lines and ensuring worker safety, these technologies are reshaping what is possible in modern manufacturing. The advent of AI and digital twin technologies has made simulation and emulation even more powerful, turning them into essential components of future smart factories.
As the line between physical and digital blurs, platforms like Emulate3D empower manufacturers to innovate, adapt, and stay resilient in an increasingly complex and demanding industrial landscape. The combination of AI, digital twins, simulation, and emulation provides manufacturers with a toolkit that enables them to respond to challenges and proactively shape the future of production. “Manufacturing is evolving, and the companies that embrace these technologies will be the ones leading the way,” Iovine concludes.