KUKA.Sim is an advanced simulation tool specifically engineered for the streamlined offline programming of KUKA robots, allowing users to enhance both system and robot performance outside of the actual production setting in a quick and easy manner. This software aids in the development of digital twins, which serve as precise replicas of future production workflows. The comprehensive 3D simulation covers the entire planning cycle, including process design, visualization of material flows, detection of bottlenecks, and the creation of PLC code. KUKA.Sim guarantees complete data consistency, ensuring that both virtual and physical controllers work with the same information, which is essential for effective virtual commissioning. By enabling the pre-testing and fine-tuning of new production lines, this method provides substantial time savings, as it allows for swift and customized planning of system and robot designs without needing any physical prototypes. Furthermore, the ability to simulate various scenarios fosters innovation and helps identify potential issues before they arise in real-world applications.