A Parallel Digital Twin Approach
Kalypso leveraged advanced emulation and simulation techniques to build comprehensive digital twins for both the AGV system and the facility itself.
AGV System Optimization
To improve the performance of the AGV material handling system, Kalypso began by gathering detailed information on AGV layout, control rules and task definitions. Using this data, the team built a digital twin of the AGV system that accurately simulated material flow and operational behavior. The model was then validated using historical data to ensure it reflected real-world conditions and performance benchmarks. With a reliable simulation in place, Kalypso conducted iterative testing to uncover throughput constraints and assess system behavior across a variety of task scenarios— enabling data-driven insights and optimization without disrupting actual operations.
Facility Design Optimization
In parallel, Kalypso addressed the broader challenge of optimizing First Solar’s facility design. This began with collecting the full set of plant layout documentation, design assumptions and controls logic requirements. Using this foundation, the team created a comprehensive digital twin of the facility to support both emulation and simulation testing. Iterative testing was then conducted to analyze material flow, evaluate commissioning efficiency and measure key operational metrics. Finally, PLC programs were connected directly to the digital twin, enabling accurate emulation of control logic and allowing First Solar to test and refine automation strategies ahead of physical deployment.
Real Results
The digital twin initiative de-risked a major capital investment while accelerating time-to-value. First Solar was able to virtually test, validate and optimize both automated systems (AGVs) and facility design—well before physical commissioning. This minimized the cost, delay and disruption that typically comes with addressing bottlenecks during live operations.
Performance & Integration
Simulation models ran 16x faster than real-time, enabling rapid iteration and insight generation.
Digital twins integrated with First Solar’s internal optimization algorithms for seamless decision-making.
Experimentation
157 bottlenecks were identified and resolved before facility launch, avoiding costly delays and redesigns.
The AGV model enabled experimentation across various task parameters and schedules—without disrupting operations.
Virtual Testing
First Solar used the digital twin environment as a virtual testing ground, adjusting layouts, sequences, and logic with confidence before deployment.
Our partnership with First Solar leveraged digital twins to minimize launch risk, streamline commissioning and maximize operational efficiency—long before the facility went live.
By proactively addressing material handling and design inefficiencies, First Solar accelerated facility readiness while enhancing system resilience. The digital twin approach ensured a smoother ramp-up, optimized throughput from day one and provided a long-term testing platform for future improvements—all without interrupting live production.
