The GPU-powered, cloud-native simulation solver provides a repeatable blueprint for integrating predictive analysis and rapid optimization in factory workflows
In sum — What to know
Optimizing manufacturing: At Microsoft Ignite, Synopsys unveiled a simulation-driven solution based on Ansys Fluent that allows manufacturers to model and optimize dynamic processes in factories.
Under the hood: The solution is powered by Nvidia Omniverse libraries and Nvidia CUDA-X libraries, and is based on Microsoft Azure’s cloud platform.
The first success: Krones AG first adopted the technology achieving accurate fluid dynamics simulations under 30 minutes.
At Microsoft Ignite, Synopsys unveiled a new simulation-driven, open-source framework that it says allows manufacturers to adjust and optimize live processes in factories in near real-time.
Based on the Ansys Fluent® fluid simulation software — and powered by Nvidia Omniverse libraries, Nvidia CUDA-X libraries, and Microsoft Azure — the framework offers real-time scenario comparisons, resource optimization outputs — and most important of all, faster simulation cycles that enable quick decision-making and near real time workflow adjustments.
Digital twin has emerged as a powerful weapon in factories and warehouses, and sets a new standard of operational excellence in the era of Industry 4.0. In packaging lines in manufacturing facilities where failed attemps can hold up production and drive up costs and time to market, digital twin provides a way to test out what-if scenarios, enhancing production efficiency and reducing operational risks. By modelling products and processes, it allows operators to make sense of how processes and jobs will run ahead of time.
Synopsys’ simulation blueprint allowed its first adopter Krones AG — a German packaging and bottling machine manufacturer — to build a physically accurate replica of its beverage production processes in just two months. Critical variables that require frequent optimizing, including bottle shape, content viscosity, and fill level, were carried along with high fidelity in this digital twin of the factory floor, said Synopsys.
Rev Lebaredian, Vice President of Omniverse and Simulation Technology at Nvidia said, “By integrating Synopsys’ accelerated physics solvers and NVIDIA Omniverse libraries on the Microsoft Azure cloud, this open framework allows manufacturers to simulate entire factory floors, test scenarios, and optimize operations in real time without disrupting physical systems.”
Computation fluid dynamic (CFD) simulators have been part of factory processes for decades, but slow simulation cycles has proved to be a thorny issue for manufacturers. The long run times are counter-productive in a setting where quick optimization of production workflows is a key requirement.
Working with collaborators like Nvidia and Microsoft, Synopsys addresses this issue with its GPU-powered, cloud-native simulation solver. The platform cuts sim time from hours to minutes, completing a 3-4 hour job in less than 5 minutes, the company claimed.
As of now, Krones’ fluid dynamics simulations run in short 30 minutes cycles, delivering faster scenario analyses, updates, and optimizations, channel partner SoftServe shared on its website.
The ability to optimize micro-factors in factory processes can enable smarter allocation of resources leading to reduced product waste and losses, and improved efficiency. Additionally, it also fosters a robust, more effective feedback system by enabling deeper collaboration between engineering, operations, and R&D teams.
The move comes amid broader efforts to streamline factory operations and embrace digital manufacturing — a shift which Ansys, that Synopsys acquired earlier this year, is at the heart of. Through collaboration with partners like Nvidia and Microsoft, Synopsys is extending accessibility of AI-enabled, digital twin-powered sim-driven insights and predictive analysis to industrial use cases.
Prith Banerjee, VP of simulation and analysis incubation group at Synopsys writes on LinkedIn, “this framework demonstrates the power of cross-industry collaboration to unlock next-generation agility and efficiency.”
