DUALIS reveals why programming is key to robot productivity

How robots unlock their full potential

• The type of robot programming is a key factor for productivity and system utilization.
• Offline Programming (OLP) enables parallel planning without production downtime and reduces programming time by up to 80%.
• OLP uses digital twins for simulation and error prevention before commissioning.
• DUALIS offers the Visual Components OLP Suite with CAD import, 18+ integrated post-processors, and one-click programming.
• Vision-based programming complements OLP for flexible, simple applications with varying part positions.
• The future lies in combining different programming methods with AI support and user-friendly interfaces.

Dresden, November 19, 2025 – Industrial robots perform critical tasks in modern manufacturing. To maximize their potential, programming plays a decisive role. Traditional online methods interrupt production, while offline programming (OLP) opens up new possibilities – without downtime.

“Many robots are underutilized – not because of their capabilities, but because of how they are programmed. Every minute of downtime during programming costs valuable production time,” explains Ralf Dohndorf, Vice President Factory Simulation at DUALIS.

Online programming of robots – directly at the production cell

For decades, robots were programmed directly at the production cell using the teach-in method. Depending on the complexity, this time-consuming process can take hours or even days, and any change in part geometry or fixtures often requires complete reprogramming. Typical disadvantages include production downtime during programming and high time expenditure for complex motion sequences. In addition, collision checking or simulation is not possible, so that errors only become apparent during actual operation.

“Especially with complex or highly varied processes, online programming quickly becomes a bottleneck. This reduces plant utilization and valuable production time is lost,” says Dohndorf.

Plan in parallel and remain productive with offline programming

With OLP, programming happens on a computer – independent of the physical robot – so production continues uninterrupted. Modern OLP uses the digital twin: movements, processes, and entire production scenarios are simulated.

Benefits of OLP

• No production downtime
• Collision, reachability, and cycle time checks before commissioning
• High reusability across similar processes

Ralf Dohndorf says: “Despite the initial additional effort, offline programming is often faster and more reliable than other methods. It delivers precise, consistent results right from the start of the design process. Companies report up to 80 percent shorter programming times.”

As a distributor of Visual Components, DUALIS helps companies integrate OLP quickly and practically — with workshops, add-ons, and user-friendly interfaces.

The Visual Components OLP Suite offers:

• Direct import of 3D CAD models
• Support for all major robot brands (18+ integrated post-processors)
• 1-click programming, and advanced calibration tools

This enables faster cell setup and virtual testing of fixtures, tools, and workflows – without risk to real production. Programs can be reused or adapted for similar cells anytime.

Vision-based programming as a complement

In addition to online and offline programming, vision-based programming has become established. This method uses cameras to detect the exact position and orientation of workpieces. The robot automatically derives its movements from this and can thus react flexibly to varying component arrangements.

The process enables a high degree of flexibility, as it does not require any fixed fixtures. It is particularly suitable for parts with random positions or tolerances. However, stable lighting and visibility conditions are a prerequisite.

Ralf Dohndorf says: “Vision-based programming is not a replacement, but a complement. It is particularly recommended for simple, repeatable tasks – but not for precise processes involving complex geometries.”

Intelligent combination is the future

DUALIS expects different programming methods to coexist in the future. OLP will gain importance through AI-driven optimization, cross-brand standards, and no-code interfaces, while teach-in remains for quick adjustments.

“Only those who combine digital planning, simulation, and advanced programming intelligently will unlock the full potential of automation. The future is flexibility — and it starts now,” Dohndorf concludes.