SAP
Digital Manufacturing
Production Planning
Asset Intelligence
Bringing Cyberwave's orchestration layer into SAP Digital Manufacturing and S/4HANA landscapes.
Industries: Discrete Manufacturing, Process Manufacturing, Automotive
The Problem with Changeovers
A robot line optimized for Product A doesn't automatically work for Product B. Different dimensions, different gripping points, different paths, different cycle times.
Traditional changeover means: stop production, bring in programmers, modify robot paths, test on the actual line (hoping you don't crash a $50k gripper), iterate until it works, then finally resume production. This takes hours—sometimes days.
The hidden cost
Every hour your line is down for changeover, you're not producing. Every test run on physical hardware risks damage. Every failed deployment erodes confidence in trying new products.
The result: manufacturers avoid changeovers. They run long batches of the same product, build inventory they might not sell, and respond slowly to market changes.
Two Ways to Change Over
Traditional changeover
1
Stop the line— Production halts
2
Programmer arrives— Scheduling delay
3
Modify robot paths— On the actual robot
4
Test run— Hope nothing crashes
5
Collision? Go back to step 3— Repeat until it works
6
Resume production— Finally
Line is down the entire time. Every iteration burns production hours.
With a digital twin
1
Build paths in simulation— Line keeps running
2
Test in simulation— Iterate freely
3
Collision? Fix it in software— No damage, no delay
4
Validate cycle times— Know before you deploy
5
Schedule line downtime— When it's convenient
6
Deploy validated program— Works first time
Steps 1-4 happen while production continues. Line stops only for final deployment.
How It Works
A digital twin of your production line lets you test new robot programs without touching the physical equipment. The robots, the conveyors, the grippers, the fixtures—all simulated with physics that matches the real world.
Build the twin
Import CAD models of your robots, cells, and products. Set up collision bodies and kinematics.
Simulate the changeover
Modify paths, test cycle times, check for collisions. Iterate as many times as you need—it's just software.
Deploy with confidence
When simulation passes, push the program to the real robots. The changeover happens during planned downtime, not trial-and-error.
This doesn't eliminate changeover time—robots still need to physically move to new positions. But it eliminates the uncertainty. You know the program will work before you deploy it.
What Actually Changes
Programming moves offline
Instead of tying up the production line for programming and testing, engineers work in simulation while the line keeps running.
Collisions caught early
A collision in simulation is a bug to fix. A collision on the floor is damaged equipment, injured workers, or destroyed product. Simulation catches problems before they're expensive.
Smaller batches become viable
When changeovers are predictable and fast, you can switch products more often. Produce what customers actually ordered instead of guessing demand months ahead.
What This Isn't
- •Not "instant" reconfiguration. Physical changeovers still take time. This makes them predictable, not instant.
- •Not fully autonomous. Engineers still write and modify robot programs. The twin validates their work.
- •Not magic. The simulation is only as accurate as the models you build. Garbage in, garbage out.
- •Not a replacement for domain expertise. You still need people who understand your process. The tool makes them more effective, not obsolete.
Partners for Flexible Manufacturing
We work with SAP, Engineering, Apeiroon, and NVIDIA on manufacturing automation projects.
Engineering
Systems Integration
Industrial Automation
Connected Factory
Delivering turnkey automation projects with Engineering's system integration expertise across Europe.
Industries: Manufacturing, Energy, Transportation
Apeiroon
Robotics Integration
Safety Systems
Retrofit Programs
Accelerating industrial robotics deployments with Apeiroon's hardware expertise and Cyberwave's orchestration.
Industries: Manufacturing, Pharmaceutical, Food & Beverage
NVIDIA
Simulation
Accelerated Computing
Perception
Combining Cyberwave's orchestration with NVIDIA's accelerated compute, Isaac, and Omniverse platforms.
Industries: Manufacturing, Logistics, Construction