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Why Your Production Line Need Digital Twin

Why Your Production Line Need Digital Twin

No matter to which industry your company belongs, making sure that your products offer the best user experience is a must if you want to grow your business. However, product development is a painstaking process that costs a lot of money and requires a lot of hard work.

The good news is that new technologies are here to make things easier. Digital Twin technology offers some surprising benefits that will help you streamline product development and production. It can help solve countless issues before they arise and save you a ton of money and effort.

Digital Twin Technology - A Real Revolution in Production

The digital twin technology is a truly revolutionary method of improving product quality and ensuring that you get the most out of every production line. Instead of creating multiple prototypes and using real-life data to find better solutions, digital twin allows you to do everything in a virtual environment.

You can use it to create a digital representation of any physical object, production process, or service. But why would you do that? It's easy! Once you recreate the entire product line in a virtual environment, you can test out every feature without actually doing it in real life. The replicated process will generate and collect data to make accurate predictions about design and performance.

It's a computer program built using real-world data. Once it has all the important details, it creates realistic simulations that predict how a process, service, or product will perform. You can integrate the entire process with IoT sensors, AI, and data analytics to get even more accurate results.

Industry 4.0 has reached a point where big data and machine learning work together in a virtual environment to improve engineering efforts, drive innovation, and boost performance. Digital twin technology is revolutionizing the way companies approach product development and production through predictive virtual development.

How Does Technology Work?

To create a digital twin of any product or production process, engineers have to use generated data to define the mathematics and physics behind the project. Once they work out all the details, they can create a mathematical model in a digital environment. 

Digital twin developers then fill in all of the details until they are sure that the digital model works exactly like the real-world counterparts. The next step is to install IoT sensors to the entire production line to generate more data that can be applied to the digital twin in real-time. That way, the digital twin can copy all of the processes providing you with detailed insight into every individual element. You can then use the digital environment to find insights that can help you improve performance and get better results in the real world. 

The amazing part of this technology is that it can handle a system of any complexity. As long as you have the right data, the model will be able to make accurate real-world predictions. DT technology is especially useful for prototyping, as it can find design problems and other issues before the physical product reaches production.

Benefits of Using Digital Twin Technology

Digital twin technology provides a few significant business benefits that can help you save time and money on product development and testing. For example, it can use the digital environment to test production lines for fatigue, efficiency, and find solutions. 

The technology has an application in many different industries. The possibilities are endless, as long as the data is accurate. If you have enough data, there's no reason why you couldn't recreate an entire city in a virtual environment and use it to improve transportation, supply chain management, and any other real-world problem.

It's especially helpful for manufacturers as it helps them improve product quality and production. The healthcare sector can also benefit from using digital twin technology coupled with IoT sensors. That way, they can use the digital environment to monitor patients remotely. These are only some of the capabilities DT tech has to offer. However, when combined with AI, ML, and IoT, the sky's the limit. Here's a quick list of the main benefits you get when using digital twin technology:

  • Improved production equipment reliability
  • Reduced downtime and performance boosts
  • Increased productivity
  • Lower risk of product availability, bad reputation, etc
  • Reduced maintenance costs due to accurate predictive maintenance 
  • Faster production times and product release times
  • Better customer experience
  • Drastic improvement in product quality and performance
  • Supply chain optimization
  • Increased ROI 

Digital Twin and IoT

IoT sensors are already changing manufacturing on many different levels. However, when IoT and digital twin technology work together, they can create all kinds of scenarios offering companies insights into how they can improve product design and production. 

Even though it might sound complicated, the process is quite simple. You feed data generated by IoT sensors placed on machines across your entire manufacturing plant. Digital twin reads the incoming data and recreates the entire process in a digital environment. Once that is in place, you can create scenarios to test different approaches and see how they affect the manufacturing process in real life. 

IoT offers maximum efficiency and allows your digital twin to optimize all processes. 

Your designers can then test out ideas virtually and figure out the best approach to product development before the production even starts. You should only remember the success of digital twin technology depends on the data you feed it. 100% accurate data will offer realistic simulations allowing you to check how machines will perform overtime to predict potential failures. Knowing details such as these can help you predict problems, eliminate production downtimes, and bring overall performance to a new level.

How Digital Twin Helps Engineers and Manufacturers

We already mentioned some of the business benefits digital twin offers, but how does it help your engineering and manufacturing departments? Well, for example, you can use it to monitor individual manufacturing components, assets, an entire system, or a specific process in real-time. But we're not talking about regular monitoring. Digital twin allows you to dig deeper into every element and get a better understanding of how it affects manufacturing.

Your engineers can then create unique machine learning applications to find particular problems using predictive maintenance. They will be able to estimate the future outcomes of many different scenarios, which can save you a ton of money. That includes accurate predictions of current processes, as well as future processes after the changes are made. In other words, you won't have to wait weeks or months to generate data and see if the changes you made offer better results.

It can have a direct impact on any manufacturing process, even waste reduction. Your engineers, manufacturers, and designers can use the digital twin together to model products, put them to the test, and find the best manufacturing equipment. 

Practices such as virtual troubleshooting and support ensure that engineers don't have any physical restraints to get the job done. The best part is - these are only some processes where the digital twin offers benefits. It can be applied to absolutely any process to make it better and more efficient. 

Digital Twin Technology is Building a Better Future 

When all things are considered, digital twin technology is one of the most revolutionary technologies in the past century. It's able to bring product development and manufacturing to a whole new level in terms of efficiency and accuracy. Not only that, but it can also help you gain a competitive edge over your competitors.

It's a technology that's already used across many industries, but we are yet to see its full potential. The bottom line is - it's a technology you need and the sooner you implement it into your manufacturing processes, the more benefits you will get.

Why Your Production Line Need Digital Twin