Defense Contractor Decreases Costs

A defense contractor operating in the automotive and defense supply chain faced significant inefficiencies in its palletized cargo-loading operations. The facility needed to evaluate multiple equipment configurations and facility layouts before committing capital to physical changes — a costly and time-consuming process when done through trial-and-error on the production floor. Loading bottlenecks were creating downstream delays, while suboptimal equipment placement contributed to unnecessary maintenance demands. Without a way to model competing scenarios objectively, decision-makers lacked the data needed to justify investment in operational changes.

To address the challenge, the contractor partnered with Rockwell Automation to build a detailed simulation model using Rockwell's Arena Simulation Software — a discrete-event digital twin platform designed for process and logistics modeling. Engineers developed a high-fidelity Arena model that replicated the existing cargo-loading environment, then used it to systematically test multiple layout configurations and equipment option scenarios in a virtual environment. This approach allowed the team to compare throughput, identify bottleneck sources, and stress-test proposed changes before any physical modifications were made. The digital twin eliminated the need for costly physical pilots and compressed the decision cycle by enabling rapid scenario iteration within a single software environment integrated into the planning workflow.

The simulation-driven approach produced measurable operational improvements across the loading operation:

• Decreased loading bottlenecks — scenario modeling identified and eliminated the root causes of congestion in the cargo-loading sequence
• Improved loading speeds — optimized layout and equipment selection reduced cycle times through the palletized cargo process
• Reduced maintenance costs — right-sizing equipment choices based on simulated utilization data lowered wear-related maintenance demands

Beyond the operational metrics, the project demonstrated the value of virtual validation: capital decisions were made with simulation data rather than assumptions, reducing the risk of costly post-installation rework.

• Simulate before you build: Digital twin modeling with tools like Arena allows SMEs to validate layout and equipment decisions without physical disruption to active operations.
• Scenario breadth matters: Running multiple competing configurations — not just one alternative — surfaces non-obvious trade-offs between throughput, cost, and maintainability.
• Maintenance cost is a hidden lever: Equipment selection optimized for throughput alone may increase maintenance burden; simulation should model lifecycle costs alongside speed.
• Defense and automotive logistics share common constraints: Palletized cargo operations face similar bottleneck dynamics regardless of end-market, making cross-industry simulation approaches transferable.