Before changing a process, investing in new equipment or modifying the layout of a factory, the industry can now test different possibilities in a virtual environment. Computer simulation has been gaining ground as a strategic tool for companies seeking to increase productivity, reduce waste and make more accurate decisions. The technology allows the creation of digital models capable of reproducing the functioning of machines, production flows, movement of materials and operational routines. Based on real data and mathematical models, it is possible to evaluate different scenarios, identify bottlenecks and predict results without the need to interrupt production or make physical changes before validation. In practice, industrial simulation acts as a virtual factory laboratory and can be applied as a Digital Twin to reproduce and analyze the behavior of production processes in a virtual environment. This approach allows the company to evaluate different alternatives, compare performance and identify the best solutions before making investments or implementing changes in the real environment. As a result, benefits such as cost reduction are obtained through the anticipation of more efficient production scenarios, the possibility of carrying out tests without interrupting the operation, greater speed in the development and implementation of improvements, the optimization of manufacturing and logistics processes and increased reliability of strategic decisions. Leax uses industrial simulation to reduce movements and prepare for production expansion. An example of this application is at Leax do Brasil, a company that received consultancy from Senai Paraná, through the Senai Institute of Productivity Technology, to analyze opportunities for improvement in its industrial process through computer simulation. The project aimed to evaluate alternatives to reduce internal movements, optimize the factory's supply and create a production structure more prepared for future expansions. From the construction of a virtual model, it was possible to reproduce the operation of operations (machining and finishing stations), considering the movement of operators, forklifts, materials and intermediate stocks. With the factory digitally represented, consultants specializing in digital transformation were able to test different layout scenarios without interfering with actual operations. The analysis identified that a significant part of the unproductive time was related to operators' movements between production stages. The evaluation of the possibilities for reorganizing intermediate stocks indicated a more efficient configuration, reducing the total travel time from 41.7 minutes to 26.06 minutes — an approximate reduction of 37.5% in movement. The result represents more time available for activities that add value to the production process and directly contributes to increased operational efficiency. Safer decisions before investment In addition to reducing travel, the study indicated the creation of a centralized logistics hub to supply the factory. The proposal makes it possible to organize internal flows, reduce routes, improve the predictability of forklift routes and free up areas previously used for decentralized storage. As a result, the company now has more space available for the possible installation of new equipment, expanding its production capacity without necessarily expanding the physical structure of the plant. According to André Gemael D’Avila, Engineering & Project Manager at Leax do Brasil, industrial simulation brought a more strategic vision about the possibilities for improvement. "The great advantage of simulation is being able to see the impacts of changes before physically carrying them out. We are able to evaluate different scenarios, understand the gains and make decisions with much more confidence, reducing risks and avoiding investments based solely on assumptions", he states. For the executive, technology also contributes to preparing the industry for the future. “More than correcting a specific problem, the project helped to structure a more efficient operation prepared for growth, maintaining productivity even with a possible expansion of the factory”, he adds. Technology as an ally of industrial competitiveness In the assessment of the Senai Institute of Productivity Technology, computer simulation represents a change in the way the industry plans its improvements. "Industrial simulation allows the company to make evidence-based decisions before making changes to the production environment. By creating a digital representation of the factory, we are able to identify opportunities, test alternatives and measure productivity gains with greater precision. This reduces risks, avoids rework and makes industrial investments more assertive", says Valdir Ribeiro da Silva, digital transformation supervisor at IST Productivity. The project developed for Leax demonstrates how technology can transform operational challenges into opportunities for improvement. Based on the scenarios evaluated virtually, a productivity gain of between 8% and 15% is estimated, considering the reduction of unnecessary movements, the optimization of supply and the increase in the availability of productive resources.