how digital twins in manufacturing can give you a competitive edge.

Manufacturers that have embraced advanced digital technologies are reaping the benefits of more efficient operations, better products, improved safety and lower costs. Yet, they’re often only scratching the surface of smart manufacturing.

Why? The simplest answer is that it’s much easier to apply innovative tech in one specific area than to reconfigure entire processes and complex systems. But all that’s changing with the introduction of digital twins in manufacturing. By bridging the gap between the physical and virtual worlds, digital twins deliver comprehensive data insights in real-time. The result? Supercharged manufacturing intelligence for a competitive edge.

what are the benefits of digital twins in manufacturing?

Most modern manufacturers are drowning in data. However, the crucial insights are often stuck in silos, lacking context, or there’s simply too much to process. Digital twins unify data into a virtual representation of a physical product, process or system. Since the digital twin mirrors its physical counterpart, it can then be used to simulate, predict and optimize end-to-end manufacturing processes.

There are many applications for digital twins in manufacturing, including:

accelerated product development

Test and validate new product designs in a virtual environment — it’s faster and minimizes the risks associated with physical prototyping.

predictive maintenance

One of the standout benefits of digital twins is their ability to predict machinery breakdowns before they occur. By analyzing historical and real-time data, digital twins can forecast when a machine is likely to fail, allowing for timely maintenance and reducing unplanned downtimes.

real-time monitoring and analysis

Continuously monitor processes to quickly identify anomalies, predict equipment failures and enhance performance.

optimize operations

Digital twin simulations help improve factory layouts, optimize resource allocation and reduce waste. Apply the technology to the entire supply chain for a holistic view of operations that can lead to better inventory management, demand forecasting and overall customer experience.

The automotive industry has made significant gains with digital twin technology. Manufacturers are cutting costs, without sacrificing safety, by using digital twins to simulate crash tests and analyze car components. In the aerospace sector, digital twins are improving aircraft performance and safety by monitoring aircraft engines in real-time.

Above all, digital twins enable manufacturers to be more agile and responsive to market changes. This technology delivers a strategic advantage, ensuring that companies can innovate and stay competitive.

what are the challenges of integrating digital twins into manufacturing processes?

As with adopting any new technology, you’ll need to first address potential roadblocks like compatibility with legacy systems and regulatory compliance. That said, our research finds that the greatest hindrance to digital enablement isn’t the technology itself. Many companies lack digitally capable workers who have the right mix of technical knowledge, practical industry skills and soft skills to effectively use digital twin technology in manufacturing.