Whether a new factory is planned or existing ones need an optimization — the design of the work environment has a direct influence on efficiency and ergonomics.

‍Cardboard Engineering allows you to simulate real workplace situations at a 1:1 scale using a modular system made of cardboard. But at what cost?

Classic cardboard engineering

Benefits and challenges

The advantages are obvious: Without expensive equipment, you can test various scenarios and optimize potentials early on for material flow, ergonomics and assembly processes.

But classic workshops also bring challenges:

• Space requirement for models is often high
• Organizational expenses are considerable
• Material costs for cardboard structures shouldn't be underestimated
• Results must be documented and transferred retrospectively
• All participants must be on site at the same time

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Virtual cardboard engineering with Halocline

Digital production planning

With Halocline, you bring Cardboard engineering into the virtual world — completely without real cardboard materials, space problems or complex workshops. Instead you can design workplaces, processes and material flows directly with Halocline — intuitive, location-independent and time-saving.

You can use Halocline flexibly on a PC or in VR — you can even plan complex production areas on an area of just 4 m². The software simplifies production planning through digital tools and interactive testing.

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Why VR instead of classic cardboard engineering?

• No need for large areas — Plan entire factory buildings on just 4 square meters of office space.
• No production stop — Test changes without the need to stop production.
• Quick adjustments — Copy, modify, and save layouts for future projects.
• Direct digital data instead of photos — Export and process planning results immediately.

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Here's how it works:

1. Create 3D models directly in VR — Plan your layout without previous CAD knowledge.
2. Test work processes — Check gripping routes and ergonomics before the first conversion.
3. Flexibly adapt designs — Copy and modify layouts in seconds.
4. Digital planning instead of photo documentation — Export your results directly to CAD or other systems.

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4x faster than classic cardboard engineering

Kautex Textron was able to significantly reduce workplace design costs with Halocline Layout:

“Depending on the scope, a layout can have up to a quarter of the effort be created and tested. The big advantage of this is the flexibility With which I can then copy, modify and save concepts for subsequent projects. Compared to classic 3D planning, I'm actually in virtual reality in the middle of a production line instead of just before and thus have the opportunity to gather early knowledge about routes or even workplace design.”
— Karl Köpke, Equipment Specialist, Kautex Textron

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Your benefits with virtual cardboard engineering

• Intuitive operation:
  No more cardboard boxes — digitally adjust equipment directly.
• Teamwork independent of time and place:
  Employees can participate in the process at any time — even when working from home.
• Less effort:
  No material handling, no rebuilding, no subsequent documentation.
• Cost savings:
  No outages, no rental costs, no cardboard — all you need is Halocline.
• Space-saving planning:
  Use digital space instead of real square meters — perfect even for small offices.

Applications for virtual cardboard engineering

• New planning of workplaces:
  Take ergonomics, space requirements and process design into account right from the concept phase.
• CIP & Lean Management:
  Identify waste, question and improve existing processes.
• Quality management:
  Identify the causes of deficiencies and eliminate them in a targeted manner.
• Strengthen employee participation:
  Direct involvement increases acceptance of change.

Who should join?

Virtual cardboard engineering is teamwork.
For your optimizations to be successful, all employees who interact with the workplace should be involved — today and in the future. Thanks to the intuitive interface, you don't need any previous technical knowledge — everyone involved can easily use the software.

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Conclusion: Less effort, more flexibility

With virtual cardboard engineering in Halocline you can plan faster, more flexible and more precise. Save space, time and costs — and experience your planning realistically in VR.

Test now for yourself how you can optimize your workplace design with Halocline.

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