The problem: you cannot experiment on a running plant
Manufacturers want higher production efficiency, less downtime and a more reliable supply chain. But testing changes on live equipment or processes is risky and disruptive, and problems often show up only after a machine has stopped.
The idea: a live virtual copy
A digital twin is a virtual replica or simulation of a physical product, process or system. Because it mirrors the real thing, you can monitor, analyse and optimise it in real time without disrupting the actual operation. Digital twins of manufacturing processes and equipment help raise production efficiency, reduce downtime and improve supply chain management.
Examples from industry
- Bridgestone is developing a commercial smart tyre that uses a digital twin to predict how long tyres will last and when they need replacing.
- BMW is using digital twin technology to create a virtual factory, giving it insight to improve workflows and fine-tune operations.
Four practical uses
We discussed these uses in a LinkedIn event, "Exploring Digital Twin Technology Solutions for Industry 4.0", with Parso.ai.
1. Predictive maintenance
A digital twin of a machine, vehicle or piece of industrial equipment is continuously updated with real-time data from sensors on the real asset. This allows:
- Real-time monitoring: spot deviations from normal operation before they cause downtime.
- Anomaly detection: machine learning finds patterns in the twin's data and predicts when maintenance is needed.
- Better maintenance scheduling: plan maintenance during planned downtime, which cuts unplanned stoppages.
2. Supply chain management
A twin of the whole supply chain network gives:
- End-to-end visibility of goods in transit, inventory levels and production.
- Risk assessment: predict delays or shortages and prepare contingency plans.
- Demand forecasting: plan inventory more accurately and avoid overstocking or stockouts.
3. Training
Twins provide realistic simulations for industries such as aviation and manufacturing. Trainees practise on a virtual copy of a complex system without risk, face realistic scenarios that build problem-solving skills, and get new scenarios as the twin is updated.
4. Employee onboarding
New employees can take a virtual tour of the workplace, learn its processes and layout through interactive guides, and complete training simulations for their role. Exploring the virtual workspace before their first day makes the transition smoother.
How to apply it
Pick one use with a clear cost attached, such as unplanned downtime on a critical line, and build the twin around it. Before you start, plan for data security, the work needed to integrate with your existing systems, and the resources the project will need.
Parso, the platform discussed at our event, is built on the experience of SEKAI, which serves clients such as Siemens Energy, Hitachi and Shemaroo. SEKAI developed the core building blocks behind Parso and holds patents for several of its features.
Next step
If you want to explore a 3D model of your machine or plant, talk to our team.
First published on the Metaverse911 blog.
Frequently asked questions
How does a digital twin help with predictive maintenance?
A digital twin helps with predictive maintenance by being continuously updated with real-time data from sensors on the real machine or equipment. This allows real-time monitoring to spot deviations before they cause downtime, machine learning anomaly detection to predict when maintenance is needed, and better scheduling so maintenance happens during planned downtime rather than as unplanned stoppages.
How can a digital twin improve supply chain management?
A digital twin of the whole supply chain network gives end-to-end visibility of goods in transit, inventory levels and production. It supports risk assessment by predicting delays or shortages so teams can prepare contingency plans, and it improves demand forecasting so companies can plan inventory more accurately and avoid both overstocking and stockouts.
Which companies use digital twin technology in their operations?
Several large companies use digital twin technology. Bridgestone is developing a smart tyre that uses a digital twin to predict tyre life, and BMW is using digital twins to create a virtual factory and fine-tune operations.