Using the digital twin to increase throughput 15 percent and improve efficiency 10 to 20 percent while reducing costs

Empowering customers using Siemens solutions

Starting as a German design office in 1988, KS Industry Solutions Sp. z.o.o. has evolved to offer computer-aided design (CAD), computer-aided manufacturing (CAM) and computer-aided engineering (CAE) solutions to all sizes of enterprises.

The company has been a trusted Siemens Digital Industries Software expert partner since 2011, delivering world-class technology backed by strong local expertise. The company aims to help customers with their advanced Industry 4.0, product lifecycle management (PLM) and digital twin solutions. Their Siemens product offerings include NX™ software, the Totally Integrated Automation (TIA) Portal, Teamcenter® software, Solid Edge® software and the Tecnomatix® portfolio.

KS Industry Solutions became a Siemens partner to offer customers industry-leading capabilities for modeling, analyzing and optimizing production systems. The company also wants to empower clients with tools that minimize risk, improve efficiency and accelerate decision making.

Automated line with HBW simulation to validate capacity and reduce material-flow risks before implementation.

Overcoming industry challenges via digital transformation

Many industries face similar challenges, especially when investing in new production lines. Challenges include reducing bottlenecks and inefficiencies in existing systems and needing to optimize throughput and logistics. Additionally, they aim to ensure the safety and ergonomics of manual operations and decrease time-to-market while minimizing the risk of wrong investment decisions.

KS Industry Solutions addresses these challenges by supporting customers to deliver complete projects, from proof of concept to full-scale implementation. Their expertise covers building realistic simulation models, running optimization studies, training and aiding clients in their digital transformation efforts. By providing a digital twin of their production systems, they help clients test and validate concepts before implementing them or creating prototypes. This reduces costs, minimizes risks and shortens project timelines.

“Our mission is to empower manufacturers with digital twin technology that reduces risks and creates measurable business value,” says Marcin Korzekwa, chief executive officer (CEO) at KS Industry Solutions.

For this, KS Industry Solutions uses Plant Simulation in the Tecnomatix portfolio to model production systems and logistics flows. They also leverage Process Simulate in the Tecnomatix portfolio, together with NX Mechatronics Concept Designer software, for virtual commissioning. These tools allow customers to test and validate concepts before committing to costly investments.

NX, Tecnomatix, Plant Simulation, Teamcenter, Solid Edge and Process Simulate are part of the Siemens Xcelerator business platform of software, hardware and services.

Robotic assembly and logistics model that optimizes resource utilization and boosts line efficiency.

Creating customized solutions and proof of concepts

One of the strongest tools in KS Industry Solutions’ arsenal is Plant Simulation for validating production concepts before companies make large investments. With this solution, customers can leverage Plant Simulation for proof-of-concept projects via subscription licenses and support, along with training and workshops for engineers and managers. Plant Simulation can be used for simulating production systems, logistics and material flows.

“Plant Simulation is not just a tool – it is a strategic enabler for smarter, safer and more efficient production,” says Grzegorz Traczyk, vice CEO and technical director at KS Industry Solutions.

KS Industry Solutions can also extend Plant Simulation to meet specific customer needs. The company’s team is experienced in creating custom-made simulation objects and methods and linking Plant Simulation with external data sources.

By starting with proof of concepts that demonstrate the return-on-investment (ROI) and reduced investment risk, customers can confidently see early on how KS Industry Solutions can help. Additionally, KS Industry Solutions blends software with engineering expertise while leveraging a holistic view from design and production planning to virtual commissioning and production systems. With a training-first mindset, the company ensures clients’ teams continue to use and grow their simulation models after project completion.

AI-driven layout optimization using genetic algorithms to reach the best-performing production setup.

Addressing broader production lifecycle challenges

Beyond Plant Simulation, KS Industry Solutions leverages several Siemens products to help customers address broader challenges across the production lifecycle. For example, using NX CAD enables companies to design and validate products efficiently, reducing errors before manufacturing begins. Leveraging NX Mechatronics Concept Designer supports virtual commissioning by integrating mechanical, electrical and automation aspects into one environment. This allows customers to identify and resolve integration issues early. Additionally, customers can use Process Simulate to optimize assembly processes and validate ergonomics and safety of manual operations, reducing risks on the shop floor. Lastly, using the TIA Portal provides a single engineering framework to configure automation systems, helping customers streamline programming and shorten commissioning time.

By combining these tools, KS Industry Solutions enables clients to minimize design errors, validate production concepts, ensure operator safety and accelerate time-to-market. Customers gain measurable benefits such as faster commissioning, smoother integration of new lines, reduced investment risk and higher confidence in automation and production decisions.

Full factory digital twin that reveals bottlenecks and maximizes overall production throughput.

Showing valuable results for improving production and manufacturing

For one automotive supplier, KS Industry Solutions helped them overcome frequent bottlenecks and unpredictable production flow. However, by helping the company integrate Plant Simulation, create a production line model and test various optimization models, they assisted the automotive supplier in increasing their throughput by up to 15 percent and reducing their cycle times.

As another example, a defense manufacturing client was planning a new assembly line and had some uncertainties. By partnering with KS Industry Solutions, they helped them use Plant Simulation to construct a proof of concept and combined it with NX Mechatronics Concept Designer software for virtual commissioning. This helped validate the client’s investment by reducing risks and establishing smoother and faster commissioning.

KS Industry Solutions also supports customers with NX CAD, helping them accelerate product development and typically reduce design errors by up to 30 percent. This shortened the time to move from concept to production. Additionally, by using NX Mechatronics Concept Designer with Process Simulate, manufacturers can validate assembly processes and perform virtual commissioning. This allowed them to cut commissioning time by as much as 20 percent and significantly reducing integration risks. Further, with the TIA Portal, customers can configure automation systems in one environment, lowering engineering effort and often reducing programming time by 15 to 25 percent.

On average, KS Industry Solutions’ customers increase production efficiency by 10 to 20 percent, significantly reduce project investment risks by approximately 25 to 40 percent and decrease implementation time by up to 30 percent.

By combining these solutions, KS Industry Solutions helps clients achieve faster time-to-market, safer and more ergonomic operations and measurable reductions in costs and downtime. Thus, customers gain greater confidence in new investments and ongoing production improvements.

Helping customers as a digital twin expert

By partnering with Siemens, KS Industry Solutions has strengthened their credibility on the market and expanded their portfolio with advanced Industry 4.0 solutions, Siemens’ knowledge and comprehensive digital twin offerings. This collaboration has opened opportunities to serve new industrial clients and deliver measurable results.

KS Industry Solutions aims to become a leading provider of Plant Simulation and digital twin solutions in central and eastern Europe. The company strives to assist manufacturers with adopting Industry 4.0 practices, becoming more efficient and building more resilient production systems. By working closely with Siemens, the company will continue to stay aligned with their innovative roadmap and deliver advanced projects to their clients.

KS Industry Solutions’ strength lies in combining deep technical knowledge of Siemens software with practical industrial engineering know-how, making them effective, reliable and focused on real-world results.