Digital Twins: The Key to Optimizing Manufacturing Processes

Applied Tech Review | Monday, July 18, 2022

Digital twins are essential to streamlining product development and operations.

FREMONT, CA: Manufacturers have been substantially spending on their digitalization as a part of the industrial revolution 4.0. To automate manufacturing processes and improves the standard, frequency, adaptability, and expense of business processes, the latter makes use of innovative technologies like the Internet of Things (IoT), Cyber-Physical Systems (CPS), cloud computing, Big Data, and Artificial Intelligence (AI). About domains like smart wealth management, quality assurance, supply chain management, and creative product development, Industry 4.0 specifically provides a variety of data-driven, added-value use cases.

Additionally, it has been clear in recent times that digital technologies play a critical role in lowering CO2 emissions and accomplishing sustainability goals. For example, forecasting effective maintenance strategies can help to reduce waste by preventing machine breakdowns.

Digital twins as Tools for Sustainability

A digital twin gives a precise online replica of interconnected physical objects. It is a virtual representation of linked manufacturing machinery that is updated in real-time to represent the real components and operational procedures that make up the environment. The digital twins will not impact the status of physical objects to imitate complex processes. Additionally, they make it possible to analyze potential physical circumstances safely and economically. The analysis and evaluation of various scenarios are essential to optimizing production processes by identifying ideal configurations in fields including equipment maintenance, production control, logistics, and supply chain management.

The digital twin is one of the most important components of Industry 4.0 applications. Precise and adaptable digital twins can be created using Cyber-Physical Production Systems (CPPS) systems, system modelling, and digital technologies like Big Data, Cloud computing, and AI. CPPS systems and IoT gadgets make it easier to gather real-time data on assets and physical production processes.

While deciding on manufacturing designs that minimize waste and maximize durability, digital twins are a highly potent instrument. For example, operational controlled variables can be established using a digital twin to eliminate product flaws and reduce waste production. A digital twin is used to verify and evaluate different periodic maintenance for one or more assets, which aids in identifying the schedule that minimizes relevant CO2 emissions, prevents unanticipated downtimes, and avoids machine breakdowns. Overall, as part of the growing twin shift of contemporary organizations, a digital twin is a critical facilitator for sustainable industrial operations.

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