Exploring the Benefits of Digital Twins in Smart Manufacturing

The digital twin concept has an intriguing history, starting unofficially in 2002 when Michael Graves introduced software for manufacturing applications. The term "digital twin" was officially coined in 2010 by NASA scientists who used it to enhance their spacecraft simulations. While this application differs from the smart factories of Industry 4.0 and modern manufacturing we discuss today, it remains a fascinating milestone in the evolution of digital twins

A ‘digital twin’ is created using software that virtually replicates physical products and their processes, including entire manufacturing systems when applied to smart factories. Once applied, the digital counterparts of twinned equipment can simulate operations to predict and then improve, if necessary, the physical equipment and whatever system they are a part of. The twins essentially provide a data rich environment that can be analysed and optimised, delivering far greater visibility into manufacturers’ production lines, resulting in improved operational efficiency and quality.

Because digital twins can simulate how manufactured parts perform under various operational scenarios in virtual environments, they are highly effective for testing component designs and evaluating performance against real-world conditions and industry standards. With this foundation, let’s delve into the intricacies of creating digital twins and explore their applications in the smart factories of Industry 4.0.

How are Digital Twins created?

The development of digital twins requires integrating data from various sources, including IoT devices, sensors, and corporate systems used by Industry 4.0 organisations. These sources might include data from supply chain management (SCM), manufacturing execution systems (MES), product lifecycle management (PLM), individual components and sensors, or a combination of all, to gather comprehensive and useful intelligence.

Advanced data analytics and machine learning are then employed to create a detailed virtual model that accurately replicates real products and processes. This enables manufacturers to simulate scenarios within their factories, forecast outcomes, and ultimately improve operations without the associated risks.

Digital Twins and Smart Manufacturing

Digital twins offer a risk-free environment that has become integral to the growth of smart manufacturing.  Through real-time monitoring and performance analysis, issues are quickly identified, and solutions are implemented without dismantling the physical twin. This ensures continuous operations, minimising or eliminating machinery downtime throughout their lifespans. Let’s look closer now at all of the benefits that digital twins bring to smart manufacturing, and get a better grasp of why the use of digital twin software is so important:

Risk-Free Prototype Testing

Digital twins enable manufacturers to test prototypes in a virtual setting, allowing for experimentation with designs and functionalities without the expenses or risks of creating or dismantling physical models. This virtual testing environment helps identify potential issues early, saving time and resources in the process. Through simulation and analysis, digital twins contribute significantly to the enhanced efficiency and productivity that define Industry 4.0.

Real-Time Performance Analysis

Sensors embedded in the established physical systems of a smart factory provide the real-time data that digital twins need to perform in their virtual environment, enabling users the ability to monitor equipment performance as it is happening, and also offering numerous valuable insights that would otherwise be unavailable. If a machine shows deviations from its performance levels, as an example, the digital twin reflects this immediately and can enable troubleshooting before major problems occur.

Process Simulation and Troubleshooting

The reason why digital twins have become so valuable is because they can simulate entire manufacturing processes, regardless of scale, with the simulations being used to identify inefficiencies within an operation. This is important as smart manufacturing relies heavily on making adjustments fast, and digital twins offer this solution without the need of unnecessary production disruptions.

Enhanced Design Processes

Digital twins also have an impact on design innovation due to the fact that they allow for the creation of designs in a digital format. These designs can then forecast how they will perform in real world scenarios or as part of a larger system, and is no different to getting to preview the future performance of a product without committing to it.

Predictive Maintenance

Another key benefit of digital twins is the ability to perform predictive maintenance. By analysing the data from a machine it becomes possible to anticipate when it will require maintenance. This proactive approach again results in the reduced downtime of equipment, and an overall improved longevity.

Operational Efficiency Improvements

Digital twins facilitate operational streamlining by enabling optimisation across various areas, such as energy consumption and resource management through ongoing refinement of the digital model. Improved manufacturing efficiency also leads to cost savings and a minimised environmental impact, aligning with modern practices.

The benefits that digital twins bring to smart manufacturing are undeniable, and by offering the range of practical applications that they do, from enhancing design procedures to advancing operational effectiveness, it is clear to see why digital twins are at the forefront of Industry 4.0. For modern manufacturers, exploring and embracing this technology is going to be vital for maintaining their competitiveness, as well as meeting future market demands.

Smart Software Development with Mobica

Our Mobicans have a grand wealth of knowledge across the entire tech-stack, and we can help you develop your own digital twin technology through our Talent-as-a-Service. From Industrial IoT to software-defined vehicles, we have a solution for every need. Contact us today and we’ll be more than happy to discuss how our experienced team can help get your project over the finish line!