Product · Free companion tool
A whole production line, on your laptop.
Digital Factory Simulator is a complete brake caliper production line you can run anywhere. No factory needed: download it, run it, and start building with MaestroHub.
The line
Four stations, one brake caliper.
From raw casting to leak-tested part, every step generates realistic production data. Product BC-2024-A, aluminium A356-T6.
OP10
CNC rough
- Spindle speed
- Vibration
- Tool wear
- Coolant pressure
OP20
CNC finish
- Spindle load
- Temperature
- Feed rate
- Tool life
OP30
Parts washer
- Wash temperature
- Wash pressure
- Detergent concentration
- Fault codes
OP40
Leak test
- Test pressure
- Leak rate
- Pressure decay
- Good and bad counts
Buffers of 10 parts between stations · 100+ sensor tags · fault simulation · energy monitoring · full part traceability
Why we built this
Evaluating an industrial context platform shouldn't require a running factory.
Most teams that want to try MaestroHub face the same challenge: they need real industrial data, such as OPC UA tags, Modbus registers, MQTT messages and production records, but connecting to a live production line for a proof of concept is slow, risky, and often blocked by IT and OT approvals. The Digital Factory Simulator removes that barrier. You get a complete, realistic manufacturing environment on your own machine, generating the same data patterns you'd see on a real shop floor.
Start your evaluation today
No procurement, no IT tickets, no factory access needed. Download the simulator, connect it to MaestroHub, and build your first OEE dashboard. Prove the value before you touch production.
Build with real-world complexity
This isn't a toy dataset. It's a 4-station production line with 100+ sensor tags, realistic fault patterns, quality defects, and energy profiles. The use cases you build here, dashboards, alerts and pipelines, transfer directly to your real factory.
No gap between demo and production
Every connection, pipeline, and dashboard you create with the simulator works with real equipment too. When you're ready to go live, swap the simulator's OPC UA server for your real PLC. Your MaestroHub configuration stays the same.
What is inside
Everything you need to simulate, monitor, and learn.
100+ sensor tags
Spindle speed, vibration, temperature, pressure, tool wear, energy consumption, with natural variance and realistic trends.
From PLC to ERP
OPC UA and Modbus TCP on the stations, an MQTT broker, MES and ERP REST APIs, SAP IDocs, and PostgreSQL with the bill of materials, the bill of process and a general ledger: the systems your real factory runs.
Faults, defects and energy
Realistic machine faults cascade through the line. Every part is tracked by serial number with quality results. Per-station energy profiles included.
Built-in web dashboard
Real-time line visualization with station status, part flow, and operator controls. See your data before you connect MaestroHub.
Stage the hard days
A plant is not always healthy. Break it on purpose and watch what your platform does.
Platform Challenges
Sixteen vendor-neutral problems a plant data platform should survive, in five groups: keep the data, trust the value, understand the plant, act under control, and plant scale. Stage each one with a button, check any platform's answer against what really happened, mark it passed, partly or failed, and print the scorecard.
Connections page
Every endpoint shows its live traffic, connected clients and recent exchanges, with a built-in probe to send test traffic.
Chaos on cue
Kill, black-hole, refuse, slow or flap any endpoint, or corrupt its frames, freeze its values and fail its logins. Each one restores itself.
The director
Call up a fault, sensor drift, tool wear, a full buffer or a faster line, and run the whole demo from one presenter screen.
Scenarios in one file
A demo is one YAML file you start, pause, step through and stop.
Writable setpoints
Write detergent, wash temperature or feed override over Modbus or OPC UA, and the process follows.
Cause and effect
A reading out of its limit makes the defects it names, at its own station and at the leak test downstream.
Maintenance orders
An order sent through the MES API stops the station and fixes what it names.
One part, four witnesses
Follow one serial number across the PLC, the broker, the MES and the ERP, and see what a frozen endpoint was hiding.
Nothing lost in the gap
The MES answers what completed since a given time, so a platform can catch up after an outage.
Run report
The simulator records what each chaos episode did and what the line produced while it ran.
What you can build
Connect the simulator to MaestroHub and start building real use cases.
OEE monitoring
Build a real-time OEE dashboard that tracks availability, performance, and quality across all 4 stations. Switch between simulation profiles and watch your OEE score change live, from 85% world-class to a 45% struggling plant.
Try itSwitch to the "Struggling" profile and watch your dashboard drop from green to red in real time.
Predictive maintenance
Create a MaestroHub pipeline that monitors OP10's spindle vibration trending upward. Set a threshold alert that fires before the spindle overload fault triggers: the exact same pattern you'd deploy on a real CNC machine.
Try itWatch vibration climb on OP10, get your alert, then see the fault confirm your prediction.
Quality analysis
Track every part by serial number through all 4 stations. Correlate OP40 leak test failures with OP20 process parameters to find the root cause: was it tool wear, temperature drift, or coolant pressure?
Try itTrace a rejected part back through every station to find where it went wrong.
Production optimization
Identify your bottleneck station by comparing cycle times and buffer levels. OP10 rough machining has a 90-second ideal cycle, against 70 for OP20 and 50 for the washer and the leak test. See how this imbalance creates starved and blocked states across the line.
Try itFind the bottleneck, then switch profiles to test what faster cycle times would do.
Get started in 3 steps
From download to your first dashboard.
- 1
Download from the portal
Go to portal.maestrohub.com and download Digital Factory Simulator for your platform. Available for Windows, macOS on Apple Silicon, and Linux.
- 2
Run the simulator
Start the simulator and choose a profile. The web dashboard opens automatically at localhost:3005, and you see the production line running with live data flowing through all 4 stations.
- 3
Connect to MaestroHub
Download the pre-configured setup file from the simulator's API page and import it into MaestroHub 3.0. The connections, hundreds of functions, the topics, eight pipelines and three dashboards arrive ready to go.
7 simulation profiles
Each profile simulates a different manufacturing scenario with realistic OEE patterns.
World ClassWorld-class manufacturing: minimal downtime, high quality, optimal throughput
85%+OEETypicalStart hereAverage manufacturing plant with a realistic mix of issues
65 to 75%OEEStrugglingA plant with significant problems: frequent stops, high scrap
45 to 55%OEEDemoA fast-paced mode that shows every data type in a short session
VariesOEEAvailability ProblemFrequent machine stops and long changeovers: availability is the bottleneck
VariesOEEQuality ProblemHigh defect rates and rework: quality is the bottleneck
VariesOEEPerformance ProblemSlow cycle times and micro-stops: performance is the bottleneck
VariesOEE
From simulator to production
Everything you build with the simulator transfers directly to real equipment. No rework.
- 1
Prove the concept with the simulator
Build your OEE dashboards, alert pipelines, and quality tracking flows using simulated data. Show stakeholders a working demo with real metrics, not a slide deck. Get buy-in before you touch a single PLC.
- 2
Swap in your real equipment
Replace the simulator's OPC UA server with your real PLC. Replace the Modbus endpoint with your actual sensor gateway. Your MaestroHub pipelines, dashboards, and alert rules stay exactly the same. They don't know or care where the data comes from.
- 3
Scale across your operation
Roll out to additional lines, factories, and sites. The patterns you validated with the simulator, your UNS topic structure, your pipeline logic, your dashboard templates, become the blueprint for your entire digital manufacturing platform.
The hours you invest building with the simulator aren't throwaway proof-of-concept work. Every pipeline, every dashboard, every alert rule you create carries over to your real equipment. The simulator just gives you a safe, fast environment to build them in.
Ready to try MaestroHub without a factory?
Download Digital Factory Simulator, connect it to MaestroHub, and start building real industrial use cases today. When you want it on your own lines, the six-week pilot is the next step.