Sicon S.r.l. is part of the Socomec Group, a French industrial company specialized in low-voltage power management.

Within the company, the process of modifying and introducing new production lines—and the resulting changes to logistics—is managed by the Industrialization department. Once production capacity is defined, a static 2D layout is created and then implemented on-site. However, there is a lack of full sharing with other departments, as well as the absence of detailed flow analysis and proactive interference calculation.

Following an initial assessment phase, during which the current production lines and raw materials warehouse were analyzed, the project focused on creating a digital model of the logistics and production area. This model was used to highlight safety issues, handling inefficiencies, and opportunities for improving overall efficiency.
The digital model provides a virtual environment in which new layout and process solutions can be tested without immediately moving to physical implementation. This enables an initial sharing phase with the various departments, a more accurate evaluation of safety aspects – both for line operators and warehouse staff (eliminating all interferences)—and a more precise assessment of efficiency before moving on to the investment phase.

The project involved virtualizing the plant to enable more accurate and collaborative decision-making, reducing rework costs caused by incorrect assessments.
Participation in the project also allowed the company to develop internal expertise in building and using a digital twin. The company’s intention is to promote the use of this tool to support its industrial operations – primarily for optimizing existing processes and facilities, as well as for designing new plants.

Digital Twin

The project initiative in question has led to several industrial impacts, as outlined below:

Sicon must focus on flexibility and responsiveness. This means rapid changes to production lines and new layouts within a short timeframe (under 3 months) to manufacture new products and keep pace with market demands.

The digital model will allow us to automatically distinguish between areas equipped with machinery and those designated for operator intervention, significantly reducing recorded near-miss incidents. The proactive evaluation of planned movements – both of vehicles and at workstations – will minimize interferences and enhance the ergonomics of the workspace.

The ability to simulate digitally eliminates waste related to scrap materials during the construction of workstations, allows for the upfront definition of packaging types, and reduces the variety of containers used. It optimizes internal space by decreasing the industrial footprint and lowers energy consumption caused by non-optimized production lines.

Digital technologies enable greater efficiency and reduce the impact of direct costs on the product. This helps keep production in Europe by making it competitive with Far East countries (such as India, China, etc.). Product quality is higher, and proximity to the European market—combined with increased flexibility—allows for shorter production lead times.