Products / Design and test

Ezbelta Digital Twin

See your mixed-model line run before you build it.

Ezbelta Digital Twin turns a Mixed Model Line Design into a running discrete-event simulation, so you can test balance, layout and staffing in software before you move a single workstation.

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Ezbelta Digital Twin process flow diagram editor showing a mixed-model line with available processes

The problem

Stop guessing about production performance

Bottlenecks stay hidden until production feels them
Staffing and resource plans rest on gut feel instead of data
Layout changes are made without knowing their true impact
Waste stays invisible until it shows up in the numbers

With Digital Twin

Find the problems in software, not on the floor

Locate bottlenecks with discrete-event simulation
See where resources are blocked, waiting or idle
Test changes risk-free before implementation
Spot waste patterns with AI-assisted lean insights

Features

From line design to a running twin

Everything needed to design a mixed-model line, simulate it and understand what it is telling you.

Mixed Model Line Design (MMLD)

A guided workflow for products, flows, processes, times and resource calculations that generates the simulation model for you.

Product mix and volume planning
Process flow design with subassemblies
Takt time and resource calculations
One-click simulation model generation

Discrete-event simulation engine

Runs your line event by event and tracks the state of every resource as it goes.

Resource states: busy, blocked, waiting, idle
Statistical warm-up period handling
Event-by-event stepping to see exactly what happened

AI-assisted lean insights

Pattern recognition that points your engineers to the waste worth investigating.

Bottleneck identification
Waste patterns across the seven wastes
Resource recommendations
Flow efficiency scoring

Visual Flow diagrams

An interactive process flow view with live simulation status and drag-and-drop editing.

Live status colors: working, idle, blocked, waiting
Drag-and-drop layout editor
Simulation playback
Automatic flow routing and connections

Analytics

The charts lean engineers actually use, built from the simulation results.

Yamazumi charts and utilization heatmaps
Resource utilization and queue analysis
Throughput and cycle time tracking
Export to Excel, CSV and PDF

Built for teams

Secure, shared models that a whole engineering team can work on.

Secure multi-user access
Model versioning and cloning
API for integration

How it works

From static design to digital twin

Step 01Design with MMLDDefine products, flows, processes and times in the guided workflow. Resource calculations are done for you.
Step 02Generate the simulationTurn the static design into a complete simulation model, with resources, flows and routing created automatically.
Step 03Visualize and runSee the process layout in Visual Flow, then run the simulation and watch every station's status.
Step 04Analyze and improveStudy utilization, bottlenecks and Yamazumi charts, change the design, and run it again.

Methodology first

AI prepares. Your team decides.

Ezbelta Digital Twin is built on the Mixed Model Manufacturing method from Leonardo Group Americas. The software does the preparation; the judgment stays with the people who know the floor.

AI prepares

Builds the simulation model from your line design
Runs the scenarios you want to compare
Flags bottlenecks and waste patterns to look at

Your team decides

Choose the line design that fits the plant
Decide staffing, buffers and kanban sizes
Decide what actually changes on the floor

Site license

See Ezbelta Digital Twin on a line like yours.

Licensed by the site: all users at one plant, onboarding, support and updates, with optional coaching from Leonardo Group Americas. Pilot programs available.

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