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シミュレーション · Minimal Factory · Rhineland

Düsseldorf future factory · robot cells and driverless transport

A modern factory as a model: robot cells, driverless transport vehicles, drones and a robot dog, plus people on the assembly line and a plant tour in ten stops.

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Trailer

Real are location, terrain and surroundings (official NRW elevation data, OpenStreetMap). Halls and processes are an interpretation of our own based on public reports; quantities, processes and times are model values. With your data, the model shows your site and your processes.

The Düsseldorf future factory is a modern van factory as a block model: twelve robot cells with four large robot arms each weld the body shells. Every body shell rides a driverless transport vehicle from cell to cell, drones fly inspection rounds, a robot dog patrols – and people work on the assembly line. Small robots, so-called cobots, fit the windows.

Five controls steer the plant: investment (one to three lines), skilled workers, supply, quality and market. A plant tour with ten stops shows delivery, cells, paint, assembly, testing and the yard. If there are too few driverless transport vehicles it gets tight, because every body shell needs one; if the yard is full, the car transporter waits.

Real are location, terrain and surroundings in Düsseldorf from official NRW elevation data and OpenStreetMap. Halls and processes are an interpretation of our own based on public reports; quantities, processes and times are model values, and one working day lasts ten seconds. The page is for museums and exhibitions, schools and universities, training and further education.

Factory tour (10 stops)

  1. 01

    Delivery

  2. 02

    Body shop · robot cells

  3. 03

    Body shop · inside a cell

  4. 04

    Paint shop

  5. 05

    Assembly · on the line

  6. 06

    Assembly · marriage

  7. 07

    Assembly · glass and cobots

  8. 08

    Logistics

  9. 09

    Inspection

  10. 10

    Yard · car transporter

A site at work

01

A site at work

Düsseldorf future factory: A modern van factory in Düsseldorf: robot arms weld in cells, each body rides on a driverless vehicle, people work on the line.

Delivery

02

Delivery

Delivery – Pressed parts arrive from other plants: floors, side panels, roofs, doors. Forklifts bring them to the cells in racks.

What is shown – why – for whom

表示内容 なぜ 対象
Delivery with pressed parts from other plants なぜShows how floors, side walls, roofs and doors reach the cells in racks. 対象museum, teaching
Twelve robot cells with four robot arms each and driverless transport vehicles なぜShows how the body shell travels from cell to cell and is welded. 対象teaching, history of technology
Paint shop with dip tank, filler, colour, clear coat and dryer なぜShows how paint robots work in the booths. 対象museum, teaching
Assembly line, marriage, windows with cobots and logistics なぜShows where people work and how driverless vehicles bring the parts. 対象museum, exhibition
Testing with light tunnel and drones なぜShows how paint, gaps and lights of every van are checked. 対象teaching, industrial heritage
Yard with car transporters, gate, canteen and robot dog なぜShows how finished vans, eight per truck, leave the plant and who comes through the gate. 対象exhibition, career guidance
Five controls with output, stockpile and daily result なぜShows connections in operations, not operating figures. 対象economics teaching
Body shop · inside a cell

03

Body shop · inside a cell

Body shop · inside a cell – The clamping frame holds the panels while the arms weld from all sides. Next to the cell: parts rack, control cabinet and a light curtain that stops the robots if anyone steps in.

Five levers, one works

04

Five levers, one works

Full investment – three lines: further line halls on the north site with body shop, paint, assembly and testing.

Films from the model

  • Above Düsseldorf future factory

    A flight across the whole site: low approach, the production line, then across the works to the long shot – everything moving, with the sound of the works.

  • Through the halls

    The factory tour glides low through the halls: from delivery through the robot cells and the paint shop to the marriage, inspection and the yard.

  • A working day in time-lapse

    In time-lapse working days pass in seconds: shifts at the gate, traffic on the supply and dispatch routes, the stockpile (yard of finished vehicles) changing along.

  • A works grows

    Investment step by step: new lines appear, the workforce grows with them, then more supply and a boom in the market.

  • Bottleneck – the works respond

    First materials run short and the plant only runs in part, then the market takes too little and the stockpile fills up – in the boom the works recover.

  • Using the software

    With the full interface: the works with five levers, slump and boom, one hall and the factory tour through the halls.

Facilities and areas in the model

  • Delivery

    Pressed parts arrive from other plants: floors, side panels, roofs, doors. Forklifts bring them to the cells in racks.

  • Robot cells

    Twelve cells with four large robot arms each weld the body. Every body rides on a driverless transport vehicle from cell to cell.

  • Paint shop

    Dip bath, primer, colour, clear coat, oven – paint robots in the booths.

  • Assembly

    People work on the line: wiring, cockpit, seats. Small robots fit the glass. Driverless vehicles bring parts from logistics.

  • Inspection

    A light tunnel and drones check every van: paint, gaps, lights. Whatever is wrong goes to rework.

  • Yard · trucks

    Finished vans wait on the yard and drive onto the car transporter – eight per truck. When it is full it leaves.

  • Logistics

    Trucks bring parts to logistics; driverless vehicles take them on to assembly.

  • Gate · canteen

    The shifts come through the gate; the canteen feeds the workforce. A robot dog patrols the body shop.

When things get tight

05

When things get tight

Yard of finished vehicles filling up – more is made than sold; when there is no room left the surplus goes at a 40 % discount.

Medium long shot

06

Medium long shot

Medium long shot – the production line: robot arms weld in cells, driverless vehicles carry the bodies.

Processes in the model

Factory tour (10 stops)

  1. 01Delivery
  2. 02Body shop · robot cells
  3. 03Body shop · inside a cell
  4. 04Paint shop
  5. 05Assembly · on the line
  6. 06Assembly · marriage
  7. 07Assembly · glass and cobots
  8. 08Logistics
  9. 09Inspection
  10. 10Yard · car transporter

From pressed parts to the van

  1. 01Delivery
  2. 02Robot cells
  3. 03Paint shop
  4. 04Assembly
  5. 05Inspection
  6. 06Yard · trucks

Expansion

  1. 01investment: further line halls on the north site
  2. 02body shop, paint, assembly and testing on each line
  3. 03set the workforce to match
  4. 04the yard in the north-east shows what is not sold

Bottleneck and recovery

  1. 01supply short – the store empties
  2. 02materials missing – the plants only run in part
  3. 03market in a slump – the stockpile grows until the fire sale
  4. 04boom – the stockpile empties, the result rises

What the model can be used for

  • Museum and exhibition

    The plant tour shows the way in ten stops: delivery, robot cells, a single cell, paint shop, assembly line, marriage, windows and cobots, logistics, testing and yard.

    対象museums, visitor centres, exhibitions

  • School and university

    What do robot cells do in body construction, and what are driverless transport vehicles for? Terms like cobot, light tunnel and andon board sit where they belong.

    対象schools, universities, vocational training

  • Humans and machines

    Where do people still work in an automated factory? On the line they fit cables, cockpit and seats while robots weld, paint and inspect. The model shows both side by side.

    対象career guidance, further training, economics teaching

  • Understanding operations

    Investment, skilled workers, supply, quality and market act at once on output, stockpile and result. It becomes visible why too few driverless vehicles slow down the whole line.

    対象economics teaching, further training

Body shop · robot cells

07

Body shop · robot cells

Body shop · robot cells – Twelve cells in four rows, each with four large robot arms. Every body rides on a driverless transport vehicle from cell to cell. Green light: cell active.

The whole software

08

The whole software

Running the works – five levers: investment, workforce, supply, quality and market; the chain shows at once what follows.

What you can change

Controls

  • Investment: Number of lines (1 to 3): more money builds more, less shuts them down; without more people they only run in part.
  • Workforce: Enough people for all lines – output rises, and so does success. Too many people cost wages without more output.
  • Supply: More material arrives – the plant no longer has to wait. Levels short, normal and double; supply security costs money.
  • Quality: More quality means less scrap and fewer breakdowns but costs testing and maintenance (levels low, normal, high).
  • Market: Slump, normal or boom. In a slump more is made than sold: the stockpile grows and success drops. In a boom the market takes more: the stockpile empties and success rises.

Disruptions

  • Too few people: Workers are missing, part of the plant stands still.
  • Material missing: Supply is not enough; once the store is empty the plants only run in part (message: “Parts store empty – supply is short”).
  • Too much built: More is made than the market takes: the stockpile grows; when it is full the surplus goes at a 40 % discount (message: “Stockpile full – fire sale at a discount”).
  • Market wants more: Demand is greater than the works can make; once the stockpile is empty orders are lost (message: “Stockpile empty – orders are lost”).
  • Bottleneck: Assembly: Parts missing.
  • Bottleneck: Yard full: The car transporter is away.
  • Bottleneck: Too few driverless transport vehicles: Every body needs one. More AGVs!

What the model brings

  • 01

    The real terrain as a stage

    Plant, tracks and surroundings stand on terrain from official elevation data. You show the site as it lies, not as a diagram.

  • 02

    A body shell on its way

    The ten-stop plant tour follows the path of the body shell. You understand the process before you steer the plant yourself.

  • 03

    Bottlenecks without damage

    Parts run short in assembly, the yard is full, there are too few driverless vehicles. You see where it gets tight first, and set it back.

  • 04

    For big screens and the browser

    Runs in the browser and on large projections. A working day in fast motion lasts ten seconds.

  • Zukunftsfabrik Düsseldorf: Eine moderne Transporterfabrik in Düsseldorf: Roboterarme schweißen in Zellen, jede Karosse fährt auf einem fahrerlosen Fahrzeug, am Band arbeiten Menschen.
    Düsseldorf future factory: A modern van factory in Düsseldorf: robot arms weld in cells, each body rides on a driverless vehicle, people work on the line.
  • Zukunftsfabrik Düsseldorf von der anderen Seite – derselbe Ort in der Nachmittagssonne aus Südwesten, mit langen Schatten der Hallen und Gerüste.
    Düsseldorf future factory from the other side – the same site in the afternoon sun from the south-west, with long shadows of halls and structures.
  • Halbtotale – die Fertigungsstraße: Roboterarme schweißen in Zellen, fahrerlose Fahrzeuge tragen die Karossen.
    Medium long shot – the production line: robot arms weld in cells, driverless vehicles carry the bodies.
  • Weit draußen bei Düsseldorf – Gelände, Häuser und Bäume stammen aus amtlichen Höhendaten, am Rand läuft die Welt weich ins Dunkel aus.
    Far out near Düsseldorf – terrain, houses and trees come from official elevation data; at the edge the world fades softly into the dark.
  • Von oben – Zukunftsfabrik Düsseldorf als Modell aus Quadern: jede Zelle ein Quader, Gebäude und Gelände nach Höhendaten und OpenStreetMap.
    From above – Düsseldorf future factory as a model of blocks: every cell a block, buildings and terrain from elevation data and OpenStreetMap.
  • Zukunftsfabrik Düsseldorf schräg von oben – Anlieferung, Roboterzellen, Lackiererei, Montage, Prüfung, Hof · Lkw auf einen Blick.
    Düsseldorf future factory from above at an angle – Delivery, Robot cells, Paint shop, Assembly, Inspection, Yard · trucks at a glance.
  • Rundherum Düsseldorf: Straßen, Gleise und Wasser aus OpenStreetMap, Häuser und Bäume aus den Höhendaten – nur die Anlage in der Mitte ist eigens gebaut.
    All around Düsseldorf: streets, tracks and water from OpenStreetMap, houses and trees from the elevation data – only the plant in the middle is built specially.
  • Auf Augenhöhe – die Fertigungsstraße, so nah wie vom Zaun aus.
    At eye level – the production line, as close as from the fence.
  • Anlieferung – Pressteile kommen aus anderen Werken: Böden, Seitenwände, Dächer, Türen. Stapler bringen sie in Gestellen an die Zellen.
    Delivery – Pressed parts arrive from other plants: floors, side panels, roofs, doors. Forklifts bring them to the cells in racks.
  • Roboterzellen – Zwölf Zellen mit je vier großen Roboterarmen schweißen die Karosse. Jede Karosse fährt auf einem fahrerlosen Transportfahrzeug von Zelle zu Zelle.
    Robot cells – Twelve cells with four large robot arms each weld the body. Every body rides on a driverless transport vehicle from cell to cell.
  • Lackiererei – Tauchbad, Füller, Farbe, Klarlack, Trockner – Lackroboter in den Kabinen.
    Paint shop – Dip bath, primer, colour, clear coat, oven – paint robots in the booths.
  • Montage – Am Band arbeiten Menschen: Kabel, Cockpit, Sitze. Kleine Roboter setzen Scheiben ein. Fahrerlose Fahrzeuge bringen die Teile aus der Logistik.
    Assembly – People work on the line: wiring, cockpit, seats. Small robots fit the glass. Driverless vehicles bring parts from logistics.
  • Prüfung – Lichttunnel und Drohnen prüfen jeden Transporter: Lack, Spaltmaße, Licht. Was nicht stimmt, geht in die Nacharbeit.
    Inspection – A light tunnel and drones check every van: paint, gaps, lights. Whatever is wrong goes to rework.
  • Hof · Lkw – Fertige Transporter warten auf dem Hof und fahren auf den Autotransporter – acht je Lkw. Ist er voll, fährt er ab.
    Yard · trucks – Finished vans wait on the yard and drive onto the car transporter – eight per truck. When it is full it leaves.
  • Logistik – Lkw bringen Teile in die Logistik; von dort fahren fahrerlose Fahrzeuge sie an die Montage.
    Logistics – Trucks bring parts to logistics; driverless vehicles take them on to assembly.
  • Tor · Kantine – Durch das Tor kommen die Schichten; die Kantine versorgt die Belegschaft. Ein Roboterhund geht durch den Rohbau Streife.
    Gate · canteen – The shifts come through the gate; the canteen feeds the workforce. A robot dog patrols the body shop.
  • Roboterzellen nah – Roboterarme schweißen in Zellen, fahrerlose Fahrzeuge tragen die Karossen.
    Robot cells close up – robot arms weld in cells, driverless vehicles carry the bodies.
  • Montage nah – Leute am Band, die Karossen ziehen im Takt weiter.
    Assembly close up – people on the line, the bodies move on in rhythm.
  • Anlieferung – Die Pressteile kommen in Gestellen aus anderen Werken. Stapler bringen sie an die Roboterzellen.
    Delivery – Pressed parts arrive in racks from other plants. Forklifts bring them to the robot cells.
  • Rohbau · Roboterzellen – Zwölf Zellen in vier Reihen, in jeder vier große Roboterarme. Jede Karosse fährt auf einem fahrerlosen Transportfahrzeug von Zelle zu Zelle. Grünes Licht: Zelle aktiv.
    Body shop · robot cells – Twelve cells in four rows, each with four large robot arms. Every body rides on a driverless transport vehicle from cell to cell. Green light: cell active.
  • Rohbau · in einer Zelle – Der Spannrahmen hält die Bleche, die Arme schweißen von allen Seiten. Neben der Zelle: Teilegestell, Schaltschrank und ein Lichtvorhang, der die Roboter stoppt, wenn jemand hineingeht.
    Body shop · inside a cell – The clamping frame holds the panels while the arms weld from all sides. Next to the cell: parts rack, control cabinet and a light curtain that stops the robots if anyone steps in.
  • Lackiererei – Vom FTS auf den Skid: Tauchbäder gegen Rost, Ofen, dann die Kabinen mit Lackrobotern – Füller, Basislack, Klarlack – und der Trockner.
    Paint shop – From AGV onto the skid: dip tanks against rust, oven, then the booths with paint robots – primer, base coat, clear coat – and the dryer.
  • Montage · am Band – Hier arbeiten die meisten Menschen. Der Hubtisch auf dem FTS hebt den Transporter auf Arbeitshöhe. Regale mit Teilen und Bildschirme mit der nächsten Aufgabe stehen direkt am Band.
    Assembly · on the line – This is where most people work. The lift table on the AGV raises the van to working height. Racks of parts and screens showing the next task stand right at the line.
  • Montage · Hochzeit – Der Hubtisch senkt sich, von unten kommt der Antrieb – beim E-Transporter die Batterie. Danach bekommt er Räder.
    Assembly · marriage – The lift table lowers and the drivetrain comes from below – for the electric van, the battery. Then it gets its wheels.
  • Prüfung – Lichttunnel für den Lack, Rollenprüfstand, Regenkabine. Drohnen fliegen Kontrollrunden über die Halle.
    Inspection – Light tunnel for the paint, rolling road, rain booth. Drones fly inspection rounds over the hall.
  • Hof · Autotransporter – Fertige Transporter warten auf dem Hof und fahren auf den Autotransporter, acht je Lkw.
    Yard · car transporter – Finished vans wait on the yard and drive onto the car transporter, eight per truck.
  • Investition klein – nur Linie 1 läuft, die übrigen Plätze liegen als Fundament mit Markierung da.
    Small investment – only line 1 runs, the other plots lie ready as marked foundations.
  • Investition voll – drei Linien: weitere Linienhallen auf der Nordfläche mit Rohbau, Lack, Montage und Prüfung.
    Full investment – three lines: further line halls on the north site with body shop, paint, assembly and testing.
  • Jede Anlage beschriftet – die Hallen von der Anlieferung bis zum Versand; oben der Werktag mit der Menge je Tag, rechts der Erfolg in einer Zahl.
    Every facility labelled – the halls from delivery to dispatch; at the top the working day with the daily output, on the right success in one number.
  • Die Fertigungsstraße beschriftet – Name und Nummer stehen direkt im Bild.
    The production line labelled – name and number right in the picture.
  • Erfolg in einer Zahl – 100 heißt: besser geht es bei diesem Markt nicht; darunter das Ergebnis je Tag, oben die Menge je Werktag.
    Success in one number – 100 means it cannot get better in this market; below it the result per day, at the top the output per working day.
  • Wo ein Regler wirkt, leuchtet ein Ring – hier nach einem Wechsel am Markt: Hof · Lkw.
    Where a lever acts, a ring lights up – here after a change in the market: Yard · trucks.
  • Material fehlt – die Zulieferung ist knapp, das Lager leer: die Montage wird gebremst, Karossen stauen sich.
    Materials missing – supply is short, the store is empty: assembly slows down and bodies back up.
  • Halde der fertigen Fahrzeuge läuft voll – es entsteht mehr, als verkauft wird; ist kein Platz mehr, geht der Überschuss mit 40 % Abschlag weg.
    Yard of finished vehicles filling up – more is made than sold; when there is no room left the surplus goes at a 40 % discount.
  • Zu wenig Leute – die Belegschaft reicht nicht für alle Linien, ein Teil der Anlage steht.
    Too few people – the workforce is not enough for all lines, part of the plant stands still.
  • Boom – der Markt nimmt mehr ab, als gerade entsteht: die Halde leert sich, auf der Abfahrt ist viel los.
    Boom – the market takes more than is being made: the stockpile empties, the dispatch route is busy.
  • Die ganze Software – oben der Werktag mit Uhr und Menge, rechts der Erfolg in einer Zahl, unten die Kacheln für Werk und Anlagen.
    The whole software – at the top the working day with clock and output, on the right success in one number, below the tiles for works and facilities.
  • Werk steuern – fünf Regler: Investition, Belegschaft, Zulieferung, Qualität und Markt; die Kette zeigt sofort, was daraus wird.
    Running the works – five levers: investment, workforce, supply, quality and market; the chain shows at once what follows.
  • Ein Regler, sofort sichtbar – Markt auf Flaute: die Lage oben erklärt den Engpass, die Halde wächst, das Ergebnis je Tag sinkt.
    One lever, visible at once – market set to slump: the status line explains the bottleneck, the stockpile grows, the daily result drops.
  • Karte einer Halle – Roboterzellen: was dort ist, wie viele Leute dort arbeiten und die Leistung der Halle.
    Hall card – Robot cells: what is there, how many people work there and the hall’s output.
  • Karte der Montage – die längste Halle, Leute am Band und die Leistung im Takt.
    Assembly card – the longest hall, people on the line and output in rhythm.
  • Werksführung – Halt 6 von 10: Montage · Hochzeit; die Kamera fährt flach durch die Hallen, je Halt ein Satz.
    Factory tour – stop 6 of 10: Assembly · marriage; the camera glides low through the halls, one sentence per stop.
  • Karte Hof · Lkw – fertige Fahrzeuge warten, bis der Autotransporter voll ist.
    Yard · trucks card – finished vehicles wait until the car transporter is full.
  • Engpass in Orange – die Zulieferung reicht nicht: Zeile oben und Lage im Werk sagen in einem Satz, was fehlt.
    Bottleneck in orange – supply is not enough: the line at the top and the works status say in one sentence what is missing.
  • Das Menü – Übersicht und Anlage, Schnitt, neu beginnen, Vorführung, Ton und andere Orte, darunter die Bedienung mit Maus, Finger und Tastatur.
    The menu – overview and plant, cutaway, restart, demo, sound and other sites, below the controls for mouse, touch and keyboard.
  • Sechzehn echte Orte – Hochöfen, Zechen, Autowerke, Häfen und eine Werft, jeder dort, wo er wirklich steht.
    Sixteen real sites – blast furnaces, collieries, car plants, harbours and a shipyard, each where it really stands.

Your site as a model

Would you like to show your plant, your museum or your industrial site like this? Write to us or call. We will send you the password for starting it on request.

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Minimal Factory: Zukunftsfabrik Düsseldorf · Roboterzellen und fahrerlose Transporte

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Basis and limits

Real are the location, terrain and buildings in Düsseldorf (official NRW elevation data and OpenStreetMap). The plant in the middle is our own simplified interpretation: quantities, processes, times and prices are model assumptions; the economy runs in time-lapse (10 seconds are one working day). Not a simulation of real operations and no cooperation with the site.

Public sources the model is based on:

  • Trade press, report on the site (31.01.2026)
  • Trade press, report on the site (2013)
  • Geobasis NRW: digital surface and terrain models DOM1/DGM1 (Data licence Germany – Zero – 2.0)
  • OpenStreetMap contributors (ODbL 1.0): streets, tracks, water, land use

More places in the model

← Minimal Factory

Real are location, terrain and surroundings (official NRW elevation data, OpenStreetMap). Halls and processes are an interpretation of our own based on public reports; quantities, processes and times are model values. With your data, the model shows your site and your processes.