Hybrid Quantum–Classical Simulation of Manufacturing Systems for Predictive Bottleneck Analysis and Process Optimization

Hybrid quantum–classical simulation offers a novel computational paradigm for addressing the increasing complexity of modern manufacturing systems. As production lines evolve into highly interconnected, data-rich environments, conventional simulation and optimization techniques often struggle to capture nonlinear interactions, dynamic bottlenecks, and stochastic fluctuations in real time. This study proposes a hybrid framework that integrates quantum-inspired state encoding, variational quantum optimization, and classical discrete-event simulation to model and predict bottleneck behavior with enhanced efficiency. By leveraging quantum subroutines—particularly Variational Quantum Eigensolvers (VQEs) and Quantum Approximate Optimization Algorithms (QAOA)—the framework accelerates combinatorial scheduling searches and dynamic resource allocation tasks. Classical processors, in turn, handle high-fidelity system modeling and domain-specific constraints. Preliminary experimental simulations demonstrate that the hybrid approach can identify emergent bottlenecks earlier than purely classical methods and improve process throughput by up to 18% in benchmark scenarios. These results highlight the transformative potential of hybrid quantum–classical systems for next-generation smart factories, enabling more resilient, adaptive, and energy-efficient manufacturing operations.