How to Design, Develop, and Deploy Effective Digital Twin Solutions for Manufacturing Industry

What if I told you that it is possible to anticipate machine failures before they occur? Or cut expenses while precisely optimizing your factory's operations? Doesn't that sound futuristic?

That is precisely what Digital Twin Technology offers the manufacturing sector. Digital twin solutions are the most advanced methodology for transforming "what if" into "what's next."

Conventional approaches frequently depend on reactive or trial-and-error approaches, which can result in resource waste and unplanned outages.

Surprisingly, however, manufacturers that use digital twin platforms claim significant maintenance cost savings and increased productivity by up to 25%.

This blog will guide you on creating, developing, and implementing efficient digital twin solutions for manufacturing.

Let’s get started!

A digital twin is a virtual version of a real item, procedure, or system. In manufacturing, this could refer to a single machine, a production line, or even the whole factory floor in digital form.

Unlike traditional models, digital twins incorporate real-time data, making it easy to track, evaluate, and improve operations.

Imagine having a mirror for your production system that does more than reflect; it also anticipates, evaluates, and provides valuable information. This is the power of the digital twin in manufacturing.

Surprising Fact

According to a report, 91% of commercial apps will employ artificial intelligence by 2025, and the market for AI is expected to reach a valuation of USD 15 trillion by 2030. Their broad use demonstrates their increasing significance in attaining operational excellence.

Digital Twin Applications in Manufacturing:

• Predictive maintenance: It stops equipment failures by seeing problems before they arise.

• Process Optimization: Evaluate and modify production processes online without compromising on-site operations.

• Quality Control: Ensure consistency and compliance by continuously monitoring and assessing the quality of the product.

Further read: Benefits of digital twins

Designing digital twin solutions for manufacturing requires a methodical, systematic approach. Every stage guarantees that your solution uses the newest technologies to produce quantifiable outcomes and is in line with your operational objectives. Let's break it down into manageable steps.

Step 1: Establish Goals and Objectives

Have you ever started a project without understanding what defines success? Even the best technologies can fail if the goals are unclear.

Why Begin Here?

Setting clear objectives guarantees that your digital twin will provide genuine value. Respond to these questions first.

• Is reducing machine downtime your goal?

• Are you aiming to improve the quality of the product?

• Are you looking to increase the effectiveness of production?

Pro tip: Make sure your objectives are SMART—Specific, Measurable, Achievable, Relevant, and Time-bound.

Step 2: Evaluate Your Technological Readiness

If your existing systems cannot accommodate a digital twin, what good is it? It's similar to ensuring your automobile is fueled before a road trip to evaluate your tech stack.

Essential Things to Consider:

• IoT Connectivity: Do your machines have IoT sensors installed?

• Data Infrastructure: Is your data accessible, well-structured, and clean?

• Software Compatibility: Are digital twin apps compatible with your present systems?

Remarkably, just 55% of manufacturers worldwide have digital twin integration-ready IoT-enabled systems.

Please read: Digital Twins and IoT

Step 3: Map Out Processes and Data Flows

Consider duplicating your processes without being aware of the precise procedures required. Process mapping guarantees that your digital twin faithfully captures reality.

Methods for Process Mapping:

• Record each process step, from acquiring raw materials to delivering the finished product.

• Determine the crucial moments when gathering data is necessary.

• Draw attention to any inefficiencies or bottlenecks that the digital twin can resolve.

Step 4: Select the Proper Tools and Digital Twin Software

What software will your digital twin be powered by? Choosing the appropriate instruments is essential for smooth functioning.

Important Points to Remember:

• Is the program able to accommodate future growth?

• Does real-time analytics offer insights that can be put to use right away?

• Will it be compatible with your current ERP or MES systems?

Step 5: Involve Key Stakeholders Early

What happens if engineers or operators are not present? Resistance to change can undermine even the most sophisticated solutions. Get your team involved right now.

Ways to Engage Them:

• Organize workshops to discuss the advantages of digital twins.

• Respond to their worries over job roles or changes to the workflow.

• Include their suggestions in the design process.

Step 6: Evaluate and Confirm the Design

Test your digital twin in a restricted setting before a large-scale launch.

• Does it function as planned?

• Are insights helpful in taking action?

Testing assists in finding holes or malfunctions before they affect operations.

Step 7: Make Plans for Future Growth and Scalability

The manufacturing sector is changing quickly. A digital twin solution should adjust to the difficulties of the future in addition to meeting the demands of the present.

Questions to Ask:

• Can the solution expand as manufacturing demands rise?

• Will it be able to integrate with emerging technologies such as analytics powered by AI?

Further read: Digital Twin in AI

What distinguishes a digital twin performing successfully from one merely "good enough"?

The tools, technology, and development methodologies that underpin it frequently hold the key to the solution.

Let's examine the steps in developing a digital twin solution that improves your production processes.

Technologies and Tools Needed

The appropriate combination of tools and technologies is necessary to create a solid digital twin software solution.

Below is a summary of the essentials:

1. IoT Devices and Sensors

Real-time data is what digital twins thrive on. IoT sensors allow your digital twin to precisely replicate real-world settings by gathering temperature, vibration, and performance indicators data.

For instance, sensors on assembly line machinery track wear and tear, providing vital information to the digital twin.

2. Data Integration Platforms

You'll need a trustworthy integration platform to compile and examine data from many sources. These platforms combine data streams to provide a smooth information exchange between your digital and physical systems.

Example: Apache Kafka.

3. Modeling and Simulation

Before making changes, you can virtually test scenarios with software simulation tools. These techniques are crucial for predicting outcomes and optimizing processes.

Examples: ANSYS, Simulink, or AnyLogic

4. Cloud Computing Platforms

Cloud systems provide the processing power required to handle and store large datasets. Additionally, digital twin software for business helps in remote access, enabling teams to monitor operations from any location.

Example: AWS IoT TwinMaker provides specific tools for digital twins.

5. AI and ML Algorithms

AI and ML improve digital twins' analytical capacities. These systems can forecast failures, spot trends, and recommend enhancements using past and current data.

Also read: Digital twin use cases

The last and most crucial step in turning your objectives into practical outcomes is deploying digital twin solutions in manufacturing.

A successful deployment guarantees that your digital twin provides secure, long-lasting operations and seamlessly integrates with current systems.

Integration with Existing Systems

Have You Thought About Compatibility?

What happens when traditional structures and cutting-edge software cross paths? Frequently, trouble.

Integration is essential to ensure that your digital twin application functions as a critical component of your manufacturing ecosystem rather than exist in a vacuum.

How to Make Sure Integration Is Smooth

1. Assess System Interoperability

Start by evaluating your current systems, including manufacturing execution systems (MES) and enterprise resource planning (ERP). Determine any gaps that can prevent integration and try to close them.

2. Exchange Data using APIs

APIs (Application Programming Interfaces) allow for easy connection between distinct systems. They guarantee seamless data transfer between analytical tools, digital twin software, and physical assets.

3. Educate Your Group

If your team cannot use the system, even the best-integrated system will not work. Educate decision-makers and operators to increase uptake and efficacy.

Providing Security and Scalability

What if tomorrow your factory doubles its output?

Is your digital twin solution going to survive? While strong security protects your operations, scalability guarantees that your system will expand with your company.

Important Scalability Strategies

1. Choose cloud-based solutions

Because cloud systems provide nearly limitless storage and processing capacity, scaling your digital twin application as your needs change is simple.

2. Build Modular Architectures

Create your software for the digital twin in modules. This enables you to include extra resources or add new features without completely redesigning the system.

3. Track and Enhance Performance

Examine system performance regularly to find bottlenecks. Using these findings, adjust the system to improve scalability.

Example 1: Boeing: Transforming Aerospace Manufacturing

Challenge:

Boeing needs to find a method to increase the precision and efficiency of aircraft manufacturing. The complex nature of contemporary designs was beyond the capabilities of conventional monitoring and quality control techniques.

Solution:

Boeing used digital twin software to produce virtual representations of its aeroplane parts. These digital twins enabled Boeing to identify possible defects, optimize manufacturing, and mimic the complete manufacturing process.

Impact:

• Reduced production errors by 40%.

• Achieved a notable decrease in the amount of time needed for assembly.

• Improved aeroplane component predictive maintenance capability.

Example 2: Siemens – Smart Factory Transformation

Challenge:

Siemens, a pioneer in industrial automation, aimed to make their Amberg, Germany, plant a prototype for the age of digital twin manufacturing.

Solution:

They used digital twin applications to build a virtual industrial model. This allowed them to model workflow modifications, monitor production lines in real time, and increase overall efficiency.

Impact:

• Over 99% of the factory's processes were completed efficiently.

• Reduced product flaws to almost zero.

• Greater manufacturing flexibility makes it possible to react to changes in the market more quickly.

Example 3: General Electric (GE) – Improving Energy Equipment Manufacturing

Challenge:

GE's energy equipment production plants frequently had equipment failures. Conventional maintenance methods were reactive and caused unscheduled downtime.

Solution:

GE introduced digital twin software, which allows for real-time equipment performance monitoring. The software's ability to forecast wear and tear made proactive maintenance regimens possible.

Impact:

• 20% less time spent on equipment failures.

• 15% increase in operating efficiency.

• Reduced yearly maintenance expenses by millions.

Suggested read: Digital twin examples

Established Industry Leadership

With more than 15 years of practical expertise, Toobler Technologies has established itself as a preferred partner for leading manufacturing companies and sectors globally.

With our extensive industry understanding and proven track record, we guarantee that every project gains from our specialist knowledge.

Creative, Upcoming Solutions

At Toobler, we create trends rather than merely following them. We use the latest technologies to develop our Digital Twin and digital transformation solutions for your manufacturing projects.

This ensures that your project initiatives are effective now and prepared to meet tomorrow's problems.

Personalized to Meet Your Specific Needs

We support perfectly tailored solutions. Because of our client-centric approach, we thoroughly understand your unique manufacturing goals and difficulties.

Our purpose is to provide tailored methods that yield observable, quantifiable outcomes.

Global Experience with Local Insight

Toobler operates in several nations and blends local knowledge with international experience. This unique combination guarantees the most outstanding results for your projects, catering to the particular needs of your market and area.

We offer the reach and expertise to support your digital transformation journey in manufacturing projects, whether you're operating locally or globally.

Please read: Which industry uses digital twins?

Below is Toobler’s case study on construction projects:

1. Nael Construction - Transforming Project Management

• Challenge: Optimizing operations and reducing costs across multiple sites.

• Solution: Implementing Digital Twin technology for real-time monitoring and data-driven decision-making.

• Outcome: Significant cost reductions, improved productivity, and enhanced decision-making capabilities.

2. Revolutionizing Inventory Management with Smart Bins

• Challenge: Managing inventory efficiently across thousands of bins.

• Solution: Integrating Digital Twins and IoT for automated inventory management.

• Outcome: Increased efficiency, reduced material replenishment time, and enhanced scalability.

For more insights and understanding refer to the case study.

Digital twin solutions in manufacturing have become a disruptive force. This provides a potent means of increasing productivity, decreasing downtime, and streamlining processes.

Concentrating on clearly defined objectives can help manufacturers achieve unprecedented levels of performance and agility. They can also evaluate technological preparedness and utilize cutting-edge tools like IoT sensors and AI.

As manufacturing continues to change, digital twins are becoming more than just an invention; they are now essential. This technology gives you the skills to stay ahead in a competitive environment.

We at Toobler are here to assist you in learning how to successfully design, develop, and deploy digital twin applications.

Contact Toobler now to begin your path to more sustainable, predictive, and effective manufacturing operations.

Contact us to find out how we might help you realize your vision.