Three Terrific Use Cases for Digital Twins in Manufacturing
For the uninitiated, a digital twin is a virtual model which is designed to accurately reflect a physical object.
The physical half of the twinning is fitted with sensors and other data collection devices which can produce information regarding the performance of the asset. In the case of machinery, this information can include energy output, temperature, efficiency, and more. This data is then fed back into the virtual model which can be used to run simulations, study performance related issues, and test improvements. The information from this can then be used to inform ongoing development of the physical object, and the cycle continues.
A digital twin should not be confused with a simulation. Where a simulation typically studies one process, a digital twin is a full virtual environment where any number of simulations can be run, and multiple processes can be studied.
According to IDC, half of manufacturers will have networked linked product and asset digital twins into digital twin ecosystems for a systems-level view of their business and a 5% reduction in quality expenses by 2024.
With all that in mind, let’s examine some real-world use cases for digital twinning and how the process is applied in manufacturing.
Product Development
Creating prototypes can be an expensive and time-consuming process. Although 3D printing technology has made the practice simpler and more accessible than ever, resin or plastic 3D prints do not always give an accurate representation of the finished product.
However, with digital twinning, the product development stage of the manufacturing process can become more streamlined and efficient than ever. Virtual models of new products can be stress tested for feasibility before any kind of production begins. According to the results, engineers can begin production or shift focus when developing a new product.
"End-to-end linking of all product data in one standard data repository across the full product lifecycle drives transparency across the entire value chain,” says McKinsey. "Product digital twins combine part and material definitions with manufacturing and in-service data. This allows for higher levels of modularization and enables product managers to make data-driven decisions about product portfolios and lifecycles.”
Personalization
We all know how important personalization is in modern marketing, but the same also goes for manufacturing. Digital twinning allows manufacturers to create and test different permutations of a product and test them independently. This means they can offer personalized products and services to the customer and present various customization options as part of a product package.
Perhaps one of the most exciting developments in this area is in the manufacture of personalized medicines. Pharma scientists can now create a digital twin of the human immune system which allows for far easier testing of new treatments, vaccines, and medicines.
"The last three years have shown us what a secretive superpower immunity really is – both for us as individuals and society as a whole,” reports Nokia. "If a digital replica of this hidden reality can bring this out into the open, then who can argue? [The project lead’s] hopes for the project are numerous and varied. He’d like to speed up drug discovery, open the door to personalized medicine […]”
Factory Performance
Manufacturers are always trying to maximize the efficiency and performance of the shop floor, so that products can be produced quickly and with the highest quality possible.
With digital twinning, data from shop floor assets can be quickly and effectively analyzed, and inefficiencies such as bottlenecks can be identified. Moreover, new practices and processes can be evaluated in a safe virtual environment to assess whether they result in higher levels of performance without negative side effects.
"When considering how digital twins can help your manufacturing, a key word to remember is visibility,” says Senior Market Research Analyst for PTC, Colin McMahon. "Organizations, especially larger, international ones, can sometimes struggle to know what exactly is happening on the ground floor. Creating digital twins of manufacturing processes perhaps provides the most complete answer ever – more than any human could be reasonably expected to see or know at any given time.”
Final Thoughts
Digital twins are empowering manufacturers to create better products, offer increased levels of customization and personalization, and streamline factory shop floor performance. Whether for the production of customer goods, or life-saving medicines and vaccines, digital twinning gives manufacturing brands the insights and actionable data they require to make decisions regarding every stage of the product production process – all within the safety of a virtual walled garden where all variables can be tightly controlled.
Virtual twinning is sure to be part of the conversation at Connected Manufacturing Forum 2023, being held in June at the Westin Buckhead Atlanta.
Download the agenda today for more information and insights.