How many automated guided vehicles does a cleanroom production facility actually need? How can airlock processes be realistically planned? And why do many cleanroom projects fail – not due to technology, but because material and personnel flows were misjudged from the start?
These were the central questions at the heart of our presentation at LOUNGES Cleanroom and Processes in Karlsruhe 2026.
For those who were unable to attend in person, we provide a concise overview here and invite you to our webinar on April 28, where we will explore the topic in much greater depth.
Why Simulation is Becoming increasingly Important in Cleanrooms
Cleanrooms are among the most demanding production environments in industry. Whether in medical technology, pharmaceuticals, or semiconductors manufacturing, success is determined not only by machines themselves, but above all by the efficiency of material flow.
Many projects share a common pattern:
the technical design works, but once operations begin, unexpected bottlenecks emerge:
- Transport routes are longer than anticipated
- Airlock become bottlenecks
- Buffer zones prove insufficient
- Personnel movement generates unnecessary waiting times
This is precisely where material flow and process simulation delivers value. It reveals how materials, personnel, and resources actually behave within the system, even before the cleanroom is built or renovated.
What we Presented at the LOUNGES in Karlsruhe
At our presentation, we showcased two real-world projects from the medical technology sector. The aim was to demonstrate how simulation not only enables in-depth analysis but also supports concrete investment decisions.
A Case in Point:
One project focused on determining the precise number of automated guided vehicles (AGVs) actually required. Initial estimates turned out to be significantly higher than what the simulation ultimately revealed as necessary.
It was only through simulation that the following became apparent:
- How peak load distribution shifts throughout the day
- Where transport congestion actually occurs
- Which routes are are subject to the highest traffic volumes
- And how buffer zones can be realistically sized
These insights proved critical to the project’s success – both from a technical and an economic perspective.
Why Traditional Planning Often Falls Short
In cleanroom environments, numerous influencing factors operate simultaneously:
- Multiple product variants
- Variable process times
- Limited airlock capacities
- Complex material flows
- Personnel movement within the same system
A single planning error can have significant cost implications down the line. This is precisely why simulation is increasingly viewed not as a nice-to-have, but as an essential strategic planning tool.
What You Can Expect from the Webinar
Following the strong response to our presentation – particularly from those who were unable to attend in person – we are making the content available online. Here is what the webinar will cover:
- How to structure a simulation project from the ground up
- What data is actually required - and what is not
- How to identify cleanroom bottlenecks at an early stage
- How to accurately determine transportation and AGV requirements
- Common planning mistakes – and how to avoid them
- Real-world case-studies from the medical technology sector
This webinar is specifically designed for:
- Production Managers
- Project Managers responsible for cleanroom planning
- Decision-makers in regulated production environments (e.g., cleanrooms)
- Companies currently planning or expanding a cleanroom facility
Webinar Invitation – April 28
If you are currently working on cleanroom planning, material flow optimization, or building a stable and scalable production system, participation is highly recommended.
Register now:
Material Flow Simulation: Virtual Planning. Real Results