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Process changes shouldn’t be tested in production

When performance drifts or issues arise, engineers need a safe way to understand what changes will actually work—before applying them in production. Fero Simulator provides a digital environment to explore process changes, test scenarios, and identify more effective setpoints without disrupting operations. Engineers can move faster from diagnosis to resolution, with greater confidence and less reliance on trial-and-error in the plant.

Process changes shouldn’t be tested in production

Virtual Model

Your digital twin mirrors the exact physics, relationships, and constraints of your real process-powered by Fero's AI and machine learning models.

Safe Simulation

Test unlimited scenarios, parameter changes, and process improvements without risking production downtime, waste, or safety issues.

Real-World Insights

Translate simulations into production decisions. Validate hypotheses, quantify expected improvements, and reduce implementation risk.

Production Simulation Capabilities

Fero's digital twin environment delivers enterprise-grade simulation capabilities designed for heavy industry.

Real-Time Process Simulation

Run your digital twin synchronously with actual operations. Watch predicted outcomes unfold in parallel with real production data.

Predictive Scenario Testing

Model thousands of what-if scenarios. Test recipe changes, equipment modifications, or market-driven parameter adjustments before deployment.

Physics-Based Modeling

Fero's digital twin captures the true physics of your process-not just correlations. Create robust, extrapolable models that work beyond historical ranges.

Virtual Commissioning

Validate new recipes, production sequences, and optimization strategies in the digital twin before touching real equipment or materials.

Uncertainty Quantification

Understand confidence intervals and risk. Know not just the expected outcome, but the range of possible results and probability distributions.

Integration with Real Operations

Your digital twin learns continuously from real-world data. Parameter updates flow automatically, keeping your virtual replica in sync with reality.

Why it matters on the plant floor

 

  • Reduce trial-and-error changes that risk quality and yield
  • Identify more effective setpoints before touching the process
  • Shorten the time between identifying an issue and fixing it
  • Improve confidence in process changes across shifts and teams
  • Protect production while exploring improvement opportunities
Find better setpoints without the risk

Before:

  • Setpoint changes tested directly in production
  • Improvements validated only after material impact
  • Conservative changes due to risk and uncertainty
  • Valuable time lost reverting unsuccessful adjustments

With Fero Simulator

  • Process changes explored in a digital environment
  • Clearer understanding of likely outcomes before action
  • Faster convergence on effective setpoints
  • Fewer production disruptions and less wasted material

Schedule a free Feasibility Study or demo

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