Optimizing Production Layout and Logistics Using a Digital Twin at UNIOR
Dr. Hugo Zupan, univ. dipl. inž., DIGITEH, d. o. o., Ljubljana; Boštjan Jegrišnik, Uroš Matavž, both UNIOR, d. d., Zreče; prof. dr. Niko Herakovič, univ. dipl. inž., Univerza v Ljubljani, Fakulteta za strojništvo
Ventil Vol. 31 (2025) 3 / Review articles / Technical Article – 1.04
Abstract:
This paper presents the use of a digital twin as a key tool for optimizing layouts and internal logistics in the company UNIOR. Following the closure of one of its production units, it was necessary to relocate several machines and technologies to two existing locations, with the goal of achieving an efficient arrangement with minimal construction interventions. Using the digital twin, we conducted precise simulations, analysed various scenarios, and optimized material flows, which enabled a more than 320% increase in the number of operations performed, a 43% reduction in material transport distances, and the elimination of the need for external logistics services. To support analysis and decision-making, we also used Sankey diagrams, which visualized the intensity and direction of material flows and significantly contributed to identifying bottlenecks and selecting the optimal layout. A comparison with the initial layout, developed based on expert knowledge without the use of simulation tools, showed that the digital twin approach leads to significantly better efficiency, improved space utilization, and more streamlined internal logistics. The paper not only presents a successful case of production capacity reorganization but also demonstrates that the digital twin is an indispensable tool for optimizing and reorganizing existing production setups in modern industrial environments.
Key words:
digital twin, production optimization, production layout, internal logistics, simulation of production processes, Sankey diagram, flexible manufacturing, smart factory
Copyright (c) 2025 Hugo Zupan
This work is licensed under a
Creative Commons Attribution 4.0 International License.
Except where otherwise noted, articles in
this journal are published under the
Creative Commons Attribution 4.0 International License.