Did you know? About 70% of tech executives are already investing in digital twins. Nearly 75% of businesses in advanced industries (automotive and aerospace) have also begun adopting these technologies.Â
Digital twins apply to the manufacturing sector as well. These virtual technologies help companies or organizations improve their physical products, processes, and/or systems. They aid in promoting process efficiency, product quality, and business scalability.
But how exactly do digital twins work? How can you employ these technologies in your manufacturing business?
Don’t worry—This page tackles what you need to know about using digital twins in manufacturing. Read on to learn its potential benefits and how to implement them for your business.
Understanding the Use of Digital Twins in Manufacturing
First things first, what is a digital twin? As the name suggests, it’s a virtual representation of a physical product, process, or system. This technology essentially applies to the manufacturing industry, where you can create a digital prototype of your actual product, manufacturing process, and equipment/machine.
The digital twin resembles real-world conditions thanks to modern technologies like artificial intelligence (AI) and the Internet of Things (IoT). This tech allows you to simulate, analyze, and optimize operations. The ultimate goal is to improve your product quality, work processes, or company systems.
NASA first used the digital twin concept to simulate spacecraft for testing, as per John Vicker’s report. However, it has soon infiltrated various industries, such as the healthcare, aviation, utility, and, yes, manufacturing sectors.Â
Think of a virtual version of something real, whether a retail product, a factory machine, or even an entire smart city. Ultimately, digital twins help monitor, test, and improve things before making changes in the actual world.
What makes a digital twin in manufacturing
A digital twin has two major components: The tangible (product) or intangible (process) and its virtual equivalent (the digital version). However, it also requires other key components to make the technology work. So, when it comes to manufacturing, here are its key components:
- Physical asset – The actual product, machine/system, and/or production line
- Digital model – A virtual version of a product/process that updates in real-time
- Data connection – Sensors powered by IoT sending data to the digital twin
- Info analytics – AI tools designed to predict issues and improve performance
- User interface – A unified dashboard used to monitor and control the digital twin
According to the Business Research Company, the global digital twin market could grow from $29.06 billion this year to $99.2 billion by 2029. The report cites it might achieve a 36.9% compound annual growth rate (CAGR).Â
This market growth was due to the digital twin’s increasing demand in healthcare (COVID-19 impact), infrastructure (smart building), and not to mention, manufacturing. Discover the benefits of digital twins in manufacturing below.
How digital twins prove beneficial in manufacturing
Manufacturing is the top industry, having adopted the digital twin technology. Other sectors that have done the same include automotive, aviation, energy, utilities, healthcare, logistics, and retail. Increasing productivity and efficiency are their top reasons for doing so. However, there is more to these than meets the eye.
As a manufacturing company, here’s how digital twins can benefit your business:
- Truly efficient processes: The digital twin makes it easier to see the critical path in manufacturing. This lets you streamline the entire process, whether reducing manual work or automating specific tasks. The outcome? Overall efficiency!
- High-quality products: The digital twin guides you in enhancing the quality of your goods or items. For instance, it assists your quality control in clothing manufacturing by identifying and addressing defects.
- Highly optimized systems: The digital twin lets you examine your systems on a micro and macro level. For example, It helps you update your machine or equipment to optimize packaging factory workflows.
- Real-time monitoring: The digital twin harnesses the impactful benefits of unified communications. With this in place, you can monitor your products or track your processes for regular upkeep and immediate repair.Â
- Substantial cost reduction: Investing in a digital twin tech requires a huge capital outlay. However, it will help you save money in the long run. Think of cutting costs with bulk shipping boxes by eliminating unnecessary expenses down the line.
- Committed sustainability: Digital twin supports sustainable manufacturing, like the use of AI in clothing production. Note: 65% of manufacturers plan to use digital twins to improve operations, and 67% see them as a way to make products more sustainable.
- Guaranteed scalability and growth: The digital twin is a means to an end. In manufacturing, this virtual tech helps improve your products, processes, and systems to scale your business.
- Case in point: Overcoming business challenges in packaging to ensure product safety and timely delivery.
Get some expert advice on employing digital twins for your manufacturing business below.
Expert Advice: How To Implement Digital Twins
Earlier, you understood what a digital twin is and how it works. More importantly, you learned how it proves beneficial for your manufacturing business. Now, it’s time for some real action—how to leverage digital twins for your manufacturing products, processes, and/or systems.
To implement digital twins for your manufacturing company, follow the crucial steps below:
Step 1. Set clear goals and find use cases
As with any business project, start by defining your clear objectives and use cases. What do you aim to achieve from investing in digital twins? And where exactly do you want to use it? In manufacturing, for example, you seek to use a digital twin to monitor your products—from supply chain to product delivery.
Tom Golubovich, Head of Marketing & Media Relations at Ninja Transfers, recommends goal-setting and use-case review for digital twin investments. “Before diving into digital twins, get clear on your goals and how you’ll use them. Whether boosting efficiency or improving quality, knowing what you want upfront helps you get the most out of the technology.”
Step 2. Pick the right tech and partners
After setting your goals and knowing its use cases, you can look for the right technology from the best service provider. Of course, a multitude of vendors offer a handful of digital twin tech. So, you must perform due diligence to find one best suited for your business and build a strong brand partnership with the provider.
Michael Nemeroff, Co-founder and CEO at RushOrderTees, suggests examining your manufacturing product/process and researching digital twin technologies. “Take the time to understand your process and research the right digital twin technology. With so many options out there, finding the right fit and the right partner will make all the difference.”Â
Step 3. Make sure data flows smoothly
A digital twin is an accurate representation of a physical product, process, or system. There needs to be a system connection for data integration. However, 98% of manufacturers report having at least one data challenge and 35% find it hard to get actionable data insights. So, plan and design how to integrate both the systems and datasets for your digital twin to work.
Take it from Jeffrey Zhou, CEO and Founder of Fig Loans. Their company leverages digital twins to streamline financing operations. “For a digital twin to work, data needs to flow seamlessly between systems. Without proper integration, you’ll struggle to get the real-time insights needed to make smarter, faster decisions.”
Step 4. Test with small before going big
Leveraging digital twins looks promising for the manufacturing industry. It can optimize various aspects of your operations, from supply chain to warehouse management to product shipping. But before the actual launch, perform a pilot run. Perform multiple tests, whether functional, performance, or integration tests.
Nick Esposito, Founder at NYCServers suggests conducting various tests to ensure they work accurately, efficiently, and seamlessly. “Before going all in, start small and test thoroughly. Digital twins have huge potential, but running functional, performance, and integration tests ensures they work smoothly and deliver the results you expect.”
Step 5. Train the team for a data-driven culture
At this point, you’ve set manufacturing goals, chosen the right tech, integrated the systems, and finally launched the digital twin. However, having robust technology is one thing; using them is another. That said, train your employees not only in using the digital twins but also in promoting a data-driven culture.
Stanislav Khilobochenko, VP of Customer Services at MacKeeper, emphasizes the need for employee training on data management. “It’s not just about having the right technology—it’s about knowing how to use it. Training your team on data management and fostering a data-driven mindset is key to making the most of digital twins.”
Final Note
There’s no denying the rise of digital twins in manufacturing. These virtual technologies can help improve your manufacturing products, processes, and/or systems. Ultimately, they can contribute to your process efficiency, product quality, and business scalability.
Consider the key steps for implementing digital twins in manufacturing shared above and reinforced by business experts.Â
Start by defining clear objectives and use cases and end by training your team to foster a data-driven mindset. Likewise, select the right tools and providers, ensure connectivity and integration, and test a pilot run before the actual launch. Ultimately, all these will help optimize your business for growth and success! Ready to leverage digital twins for your manufacturing business? Take advantage of our leading platform designed for brands and manufacturers.
