Cost Optimization in Manufacturing with Digital twin

Bhagyashri Kambale | May 05, 2022 | 761 views
COST OPTIMIZATION IN MANUFACTURING
Digital twins appear to be beneficial in cutting expenses for many industries. A growing number of companies in the manufacturing industry, as well as healthcare, oil & gas, and other industries, are using digital twin features to better understand and respond to changing business conditions.

Digital twins can be used to save costs at numerous levels or segments of your business. Their use raises awareness of situations and helps businesses make better decisions. This technology has been applied to:

  • Change to standard care and conditional support in the railways
  • Use predictive care to foresee major impacts on the oil and gas industry
  • Monitor patients in real-time to improve comfort and avoid life-threatening scenarios

So, how do digital twin solutions assist manufacturers in cutting production costs?

Digital twins enable manufacturers to detect early mechanical defects, allowing for faster or cheaper repairs. Companies can save money by adapting to changing circumstances. For example, a corporation may automatically plan repairs to minimize performance impact.

Many companies use digital twins to cut expenses in various operating scenarios. In this article, we will look at situations to help recognize the benefits of digital twins.


Why Use a Digital twin?


Better R&D

The adoption of digital twins provides more effective product research and design. It also generates large amount of data about expected performance or results in the process. This data can provide insights that enable businesses to make necessary product refinements before initiating production.


Superior efficacy

The use of digital twins can be beneficial even after a new product has been put into production. This can help mirror and monitor production processes to achieve and maintain optimal efficiency throughout the whole manufacturing process.


Product end-of-life

As far as product lifecycle management is concerned, digital twins can assist manufacturers in determining what to do with products that have reached the end of their expected life and require final processing, whether through recycling or other means. They can figure out which product materials can be gathered with the help of digital twins.


Cost Optimization in Manufacturing using Digital twin


Transportation Cost Optimization

Digital twins are commonly employed in high-value rolling commodities like trains to improve fuel efficiency and competitiveness (i.e., predictable repairs). However, in the case of passenger automobiles, cost savings have been recorded (for example, improving security maintenance at passenger doors and train wheels).

When switching from conventional to state-based prevention in stock care, the rail transport operator claimed an average 10% savings.


Oil and Gas Cost Optimization

Companies frequently utilize digital twins to simulate and analyze functions like oil metals, pipelines, and processing plants. Among the business objectives supported by forecasting adjustments, machine learning, and other analyses are an increase in automated excavation or processing processes, a reduction in off-peak hours (FTE), and downtime, and the extension of the life of high-value assets.

The oil and gas businesses claimed that historical data forecasts for building repairs had been discovered near a substantial portion of their offshore oil production. This gave them time to lead security operations. They saved a week of unplanned unemployment and production expenditures. In less than a year, their digital investment has returned twice as much as before.


Supply Chain Cost Optimization

Businesses are increasing their investment in IoT and supply chain monitoring. Utilizing modern supply chain characteristics such as digital twins can assist businesses in achieving enhanced business results.

Monitoring the location and condition of high-value assets can assist in identifying anomalies that suggest an increased risk of theft. Additionally, this technology can be utilized to determine the location of assets for the purpose of recovery. While digital twins in many of these circumstances are straightforward – simply a location – in others, the supervised data may include natural characteristics such as the temperature inside the frozen container, generator fuel levels, or ways of detecting asset depletion or interruption.


Final Word

Is a digital twin necessary for your business? Yes, most certainly. By creating a comprehensive virtual picture of a company's processes, digital twins remove the element of uncertainty from decision-making. According to Gartner, 13% of organizations utilizing IoT already have digital twins in place, while 62% are either implementing or planning to do so. Hence, do not hesitate to deploy a digital twin in your organization, as it is worthwhile to invest in a digital twin that will help you lower overall production costs in the long run.


FAQ


Why is a digital twin necessary?

Digital twins are becoming vital in business. By making a digital copy of the physical assets of a product or service in an industry, digital twins help with data analysis and give people a way to check how things work before they happen. This way, they can develop a solution to any problem before it happens.


What data should be in the digital twin model?

The concept of the digital twin is based on three unique components: the physical product, the digital/virtual product, and the connections between the two.


How much does a digital twin cost?

According to some experts’ estimations, the cost of implementing a digital twin is $50,000 or less. Complex processes will necessitate a substantial investment and a lengthy implementation period to model.

Spotlight

Amendia

Headquartered in a state of the art manufacturing facility in Marietta, Georgia, Amendia is a leading provider of innovative medical devices used during spinal surgical procedures. Founded in 2008, Amendia’s mission is to exceed surgeon and patient expectations by creating balanced solutions with disruptive technologies for medical devices paired with biologics and instrumentation.

OTHER ARTICLES

Achieving Interoperability in an Industry 4.0 Factory

Article | February 11, 2020

As a part of the Industry 4.0 movement, factory engineers are increasingly adopting some form of industrial Ethernet to interconnect the machines and other equipment implementing their production processes. Ethernet has been around in multiple forms for over 40 years. Most of it serves the IT community by interconnecting PCs and other equipment to a company LAN. Because of its flexibility, Ethernet has been adapted to many industrial uses.

Read More

The Impact of Coronavirus on Electronic Manufacturing

Article | February 11, 2020

Wuhan, the epicenter of the outbreak, is considered a crucial hub in the middle of China, a place of high importance for the production of automobiles, electronics, optics, and fiber optics. Wuhan and surrounding cities in the Hubei province are currently on a government-imposed quarantine at a scale the world has never seen before, some Chinese officials have referred to the situation as warlike.

Read More

Digitalizing Your Manufacturing Ecosystem

Article | February 10, 2020

Making digitalization work for you requires an understanding of your manufacturing ecosystem. Standards - such as ISA-95 - only guide you on a journey to more deeply comprehend the workings of your unique process for manufacturing your products. A batch manufacturing ecosystem often includes campaign management. Campaign management is not mentioned in ISA-95, which only speaks generally of order processing.

Read More

4 Food and Beverage Manufacturing Trends on Tap for 2020

Article | February 10, 2020

It’s the food and beverage industry’s job to appeal to consumer tastes by keeping tabs on what’s hot and what’s not. In the 1990s, for instance, fat free or reduced fat was all the rage, evidenced by the variety of products with such descriptions featured in bold typeface on cartons, cardboard and boxes. Fast forward to today, thanks in part to advancements in nutrition science, fat is back and is recommended in low-carb diets such as Atkins and Keto.

Read More

Spotlight

Amendia

Headquartered in a state of the art manufacturing facility in Marietta, Georgia, Amendia is a leading provider of innovative medical devices used during spinal surgical procedures. Founded in 2008, Amendia’s mission is to exceed surgeon and patient expectations by creating balanced solutions with disruptive technologies for medical devices paired with biologics and instrumentation.

Related News

MANUFACTURING TECHNOLOGY, ROBOTICS AND AUTOMATION

SVT Robotics and Kardex Solutions Partner to Enable Complete End-to-End Pick and Pack Solution

SVT Robotics | March 17, 2023

SVT Robotics, a leading enterprise software provider for the rapid integration of industrial robotics, and Kardex Solutions, a leading Global Business Partner of AutoStore™ and intralogistics solution provider of automated storage, retrieval, and material handling systems, today announced a strategic partnership. The partnership now enables Kardex Solutions customers to easily deploy and integrate AutoStore systems with additional automation technology by leveraging the power of the SVT Robotics SOFTBOT® Platform. Building upon its Kardex Control Center WES technology, Kardex Solutions has connected its software to the SOFTBOT Platform to enable a complete end-to-end pick and pack solution. Through this partnership, Kardex Solutions customers can quickly integrate and deploy an AutoStore system and Kardex Control Center with other warehouse functions, such as a WMS. "Agility is one of the greatest advantages that companies can leverage. When it comes to automation, it's imperative that businesses can quickly deploy supply chain technologies as well as reconfigure them to meet their evolving needs," said A.K. Schultz, CEO of SVT Robotics. "We're excited to partner with Kardex Solutions to offer their customers a simple and effective method for rapid automation adoption." "By coupling Kardex Control Center with the SOFTBOT Platform, we're able to provide our customers with a true 'easy button' approach to automation," said Mitch Hayes, President of Kardex Solutions. "What we've done is eliminate the complexities around warehouse automation by creating a pathway for AutoStore systems to easily integrate with technologies commonly found in distribution centers. We're proud to offer this complete solution to our customers." About SVT Robotics SVT Robotics is an enterprise software company that's revolutionizing robot deployments in the warehousing and manufacturing industries. SVT's tech-agnostic, low-code SOFTBOT Platform enables companies to integrate robots, automation, IoT technology, or human productivity tools for any task in just days or weeks. About Kardex Solutions Kardex Solutions is part of the Kardex Group, which is a leading intralogistics solution provider of automated storage, retrieval, and material handling systems and an AutoStore Global Business Partner. The Kardex mission is to provide solutions and services to increase the efficiency in storing and handling of goods and materials on a global scale.

Read More

MANUFACTURING TECHNOLOGY

3D Systems Collaborates with TE Connectivity on Innovative Solution to Additively Manufacture Electrical Connectors

Globenewswire | March 24, 2023

3D Systems today announced its collaboration with TE Connectivity, a world leader in connectors and sensors, to jointly develop an additive manufacturing solution to produce electrical connectors meeting stringent UL regulatory requirements. The solution comprising 3D Systems’ Figure 4® Modular, Figure 4 material, 3D Sprint® software, and services was designed to meet TE Connectivity’s unique requirements for material performance and high tolerance, reliable printing. The foundation of the solution is a newly developed photopolymer 3D Systems engineered specifically to meet TE Connectivity’s requirements. In addition to a world-class flammability rating at 0.4mm thickness, it is the first known printable photopolymer to complete a UL®1-recognized long-term thermal aging (RTI) study. This material combined with an optimized print process enables the necessary reliability and accuracy required for TE Connectivity’s products. Using 3D Systems’ Figure 4 technology, the combination of new material properties, speed, and accuracy allows the production of rugged industrial products for the first time, targeted at appliances, cellular and data-center applications. Additive manufacturing provides TE Connectivity freedom of design to create complex geometries that would be difficult to create using injection molding. It increases flexibility for low volume, quick turn production runs, and tooling avoidance, allowing TE to quickly demonstrate its capabilities and its customers to more efficiently meet demand. 3D Systems’ Application Innovation Group (AIG) collaborated with TE Connectivity’s team to develop a full production workflow from design to a finished connector. The program included the development and UL certification of a new Figure 4 material. UL regulatory approval has been obtained, including UL94 V0 flame rating at 0.4mm, Glow Wire Ignition (GWI) of 800°C, Comparative Tracking Index (CTI) of 600V (equivalent to a PLC of 0), and Relative Temperature Index (RTI) for long-term electrical and mechanical use of 150C and 130C, respectively. “As 3D printing technology evolves, we’re seeing more opportunities for using it to manufacture products for customers who need a low volume of parts in a short timeframe,” said Philip Gilchrist, VP and segment chief technology officer for Communications Solutions at TE Connectivity. “Our work with 3D Systems enables us to provide our customers with functional parts in just weeks instead of months.” “Customer-centric innovation is at the core of everything we do,” said Reji Puthenveetil, executive vice president, industrial solutions, 3D Systems. “The collaboration with TE Connectivity provided the understanding and requirements of the unique application being addressed and enabled the development of the solution. Our materials scientists and print process experts worked very closely with the TE team to formulate a material that, when used in conjunction with our Figure 4 technology, delivered on the high quality, high-reliability standards their customers have come to expect. This is yet another example of how 3D Systems is partnering with industry leaders to accelerate innovation and build competitive advantage through additive manufacturing solutions.” About 3D Systems More than 35 years ago, 3D Systems brought the innovation of 3D printing to the manufacturing industry. Today, as the leading additive manufacturing solutions partner, we bring innovation, performance, and reliability to every interaction - empowering our customers to create products and business models never before possible. Thanks to our unique offering of hardware, software, materials, and services, each application-specific solution is powered by the expertise of our application engineers who collaborate with customers to transform how they deliver their products and services. 3D Systems’ solutions address a variety of advanced applications in healthcare and industrial markets such as medical and dental, aerospace & defense, automotive, and durable goods. About TE Connectivity TE Connectivity is a global industrial technology leader creating a safer, sustainable, productive and connected future. Our broad range of connectivity and sensor solutions, proven in the harshest environments, enable advancements in transportation, industrial applications, medical technology, energy, data communications and the home. With more than 85,000 employees, including over 8,000 engineers, working alongside customers in approximately 140 countries, TE ensures that EVERY CONNECTION COUNTS.

Read More

MANUFACTURING TECHNOLOGY, PROCUREMENT & SUPPLY CHAIN

Zebra and Ivanti Wavelink Partner to Boost Warehouse Productivity

Ivanti | March 16, 2023

Ivanti Wavelink today announced that it is merging Ivanti Wavelink and Zebra Autonomous Mobile Robots (AMRs) in manufacturing and warehouse facilities. Ivanti Wavelink, the supply chain operation unit at Ivanti, and Zebra Technologies Corporation, an inventor at the forefront of its line of business with solutions and partners that deliver a performance edge, will accelerate the effectiveness of automation. The solution will boost productivity and efficiency while letting workers focus on high-value tasks. The integration of Ivanti Wavelink's Velocity Voice Direction platform with Zebra's Fetch AMRs will increase automation for businesses that seek to streamline complex material transportation procedures. Zebra AMRs may now be controlled by Velocity apps or voice direction without modifying the host WMS, ERP, or other enterprise systems, making robots easy to integrate into workflows. Robots can reduce manual material handling by 50%, enhancing production, workflow, and safety. The Velocity platform guides Zebra AMRs through workflows, which adds value to operations for moving and handling goods. Ivanti Neurons for IIoT insights give customers visibility into AMR status, including what task each robot is doing and any delays or disturbances. James Lawton, General Manager and Vice President of Robotics Automation at Zebra Technologies, remarked, "Our customers recognize that automation is key to the future of their operations and are ready to make investments in strategies and solutions that can get them where they need to be quickly." He added, "Integrating Ivanti Wavelink's Velocity platform with our Fetch AMRs brings the kind of sophistication customers are looking for – in this case, integrating voice commands with AMRs, so work gets done quickly, correctly and without friction." (Source –Business Wire) Brandon Black, Senior Vice President and General Manager at Ivanti, stated, "This partnership is another example of how our 'hands off the host app' approach that is a core tenet of the Ivanti Wavelink's Velocity platform can aid in increasing productivity, accuracy, and safety. Because Velocity interfaces with existing enterprise applications without the need to migrate or modify the host application, there is minimal implementation time." (Source –Business Wire) About Ivanti Ivanti discovers, manages, secures, and services IT assets from cloud to edge. It serves over 40,000 customers, including 96 of Fortune 100. It values all perspectives at Ivanti and works toward a more sustainable future for its partners, customers, staff, and the world. Customers choose Ivanti to discover, manage, secure and service their IT assets from cloud to edge to deliver excellent digital employee experiences and improve the IT and security teams' productivity and efficiency.

Read More

MANUFACTURING TECHNOLOGY, ROBOTICS AND AUTOMATION

SVT Robotics and Kardex Solutions Partner to Enable Complete End-to-End Pick and Pack Solution

SVT Robotics | March 17, 2023

SVT Robotics, a leading enterprise software provider for the rapid integration of industrial robotics, and Kardex Solutions, a leading Global Business Partner of AutoStore™ and intralogistics solution provider of automated storage, retrieval, and material handling systems, today announced a strategic partnership. The partnership now enables Kardex Solutions customers to easily deploy and integrate AutoStore systems with additional automation technology by leveraging the power of the SVT Robotics SOFTBOT® Platform. Building upon its Kardex Control Center WES technology, Kardex Solutions has connected its software to the SOFTBOT Platform to enable a complete end-to-end pick and pack solution. Through this partnership, Kardex Solutions customers can quickly integrate and deploy an AutoStore system and Kardex Control Center with other warehouse functions, such as a WMS. "Agility is one of the greatest advantages that companies can leverage. When it comes to automation, it's imperative that businesses can quickly deploy supply chain technologies as well as reconfigure them to meet their evolving needs," said A.K. Schultz, CEO of SVT Robotics. "We're excited to partner with Kardex Solutions to offer their customers a simple and effective method for rapid automation adoption." "By coupling Kardex Control Center with the SOFTBOT Platform, we're able to provide our customers with a true 'easy button' approach to automation," said Mitch Hayes, President of Kardex Solutions. "What we've done is eliminate the complexities around warehouse automation by creating a pathway for AutoStore systems to easily integrate with technologies commonly found in distribution centers. We're proud to offer this complete solution to our customers." About SVT Robotics SVT Robotics is an enterprise software company that's revolutionizing robot deployments in the warehousing and manufacturing industries. SVT's tech-agnostic, low-code SOFTBOT Platform enables companies to integrate robots, automation, IoT technology, or human productivity tools for any task in just days or weeks. About Kardex Solutions Kardex Solutions is part of the Kardex Group, which is a leading intralogistics solution provider of automated storage, retrieval, and material handling systems and an AutoStore Global Business Partner. The Kardex mission is to provide solutions and services to increase the efficiency in storing and handling of goods and materials on a global scale.

Read More

MANUFACTURING TECHNOLOGY

3D Systems Collaborates with TE Connectivity on Innovative Solution to Additively Manufacture Electrical Connectors

Globenewswire | March 24, 2023

3D Systems today announced its collaboration with TE Connectivity, a world leader in connectors and sensors, to jointly develop an additive manufacturing solution to produce electrical connectors meeting stringent UL regulatory requirements. The solution comprising 3D Systems’ Figure 4® Modular, Figure 4 material, 3D Sprint® software, and services was designed to meet TE Connectivity’s unique requirements for material performance and high tolerance, reliable printing. The foundation of the solution is a newly developed photopolymer 3D Systems engineered specifically to meet TE Connectivity’s requirements. In addition to a world-class flammability rating at 0.4mm thickness, it is the first known printable photopolymer to complete a UL®1-recognized long-term thermal aging (RTI) study. This material combined with an optimized print process enables the necessary reliability and accuracy required for TE Connectivity’s products. Using 3D Systems’ Figure 4 technology, the combination of new material properties, speed, and accuracy allows the production of rugged industrial products for the first time, targeted at appliances, cellular and data-center applications. Additive manufacturing provides TE Connectivity freedom of design to create complex geometries that would be difficult to create using injection molding. It increases flexibility for low volume, quick turn production runs, and tooling avoidance, allowing TE to quickly demonstrate its capabilities and its customers to more efficiently meet demand. 3D Systems’ Application Innovation Group (AIG) collaborated with TE Connectivity’s team to develop a full production workflow from design to a finished connector. The program included the development and UL certification of a new Figure 4 material. UL regulatory approval has been obtained, including UL94 V0 flame rating at 0.4mm, Glow Wire Ignition (GWI) of 800°C, Comparative Tracking Index (CTI) of 600V (equivalent to a PLC of 0), and Relative Temperature Index (RTI) for long-term electrical and mechanical use of 150C and 130C, respectively. “As 3D printing technology evolves, we’re seeing more opportunities for using it to manufacture products for customers who need a low volume of parts in a short timeframe,” said Philip Gilchrist, VP and segment chief technology officer for Communications Solutions at TE Connectivity. “Our work with 3D Systems enables us to provide our customers with functional parts in just weeks instead of months.” “Customer-centric innovation is at the core of everything we do,” said Reji Puthenveetil, executive vice president, industrial solutions, 3D Systems. “The collaboration with TE Connectivity provided the understanding and requirements of the unique application being addressed and enabled the development of the solution. Our materials scientists and print process experts worked very closely with the TE team to formulate a material that, when used in conjunction with our Figure 4 technology, delivered on the high quality, high-reliability standards their customers have come to expect. This is yet another example of how 3D Systems is partnering with industry leaders to accelerate innovation and build competitive advantage through additive manufacturing solutions.” About 3D Systems More than 35 years ago, 3D Systems brought the innovation of 3D printing to the manufacturing industry. Today, as the leading additive manufacturing solutions partner, we bring innovation, performance, and reliability to every interaction - empowering our customers to create products and business models never before possible. Thanks to our unique offering of hardware, software, materials, and services, each application-specific solution is powered by the expertise of our application engineers who collaborate with customers to transform how they deliver their products and services. 3D Systems’ solutions address a variety of advanced applications in healthcare and industrial markets such as medical and dental, aerospace & defense, automotive, and durable goods. About TE Connectivity TE Connectivity is a global industrial technology leader creating a safer, sustainable, productive and connected future. Our broad range of connectivity and sensor solutions, proven in the harshest environments, enable advancements in transportation, industrial applications, medical technology, energy, data communications and the home. With more than 85,000 employees, including over 8,000 engineers, working alongside customers in approximately 140 countries, TE ensures that EVERY CONNECTION COUNTS.

Read More

MANUFACTURING TECHNOLOGY, PROCUREMENT & SUPPLY CHAIN

Zebra and Ivanti Wavelink Partner to Boost Warehouse Productivity

Ivanti | March 16, 2023

Ivanti Wavelink today announced that it is merging Ivanti Wavelink and Zebra Autonomous Mobile Robots (AMRs) in manufacturing and warehouse facilities. Ivanti Wavelink, the supply chain operation unit at Ivanti, and Zebra Technologies Corporation, an inventor at the forefront of its line of business with solutions and partners that deliver a performance edge, will accelerate the effectiveness of automation. The solution will boost productivity and efficiency while letting workers focus on high-value tasks. The integration of Ivanti Wavelink's Velocity Voice Direction platform with Zebra's Fetch AMRs will increase automation for businesses that seek to streamline complex material transportation procedures. Zebra AMRs may now be controlled by Velocity apps or voice direction without modifying the host WMS, ERP, or other enterprise systems, making robots easy to integrate into workflows. Robots can reduce manual material handling by 50%, enhancing production, workflow, and safety. The Velocity platform guides Zebra AMRs through workflows, which adds value to operations for moving and handling goods. Ivanti Neurons for IIoT insights give customers visibility into AMR status, including what task each robot is doing and any delays or disturbances. James Lawton, General Manager and Vice President of Robotics Automation at Zebra Technologies, remarked, "Our customers recognize that automation is key to the future of their operations and are ready to make investments in strategies and solutions that can get them where they need to be quickly." He added, "Integrating Ivanti Wavelink's Velocity platform with our Fetch AMRs brings the kind of sophistication customers are looking for – in this case, integrating voice commands with AMRs, so work gets done quickly, correctly and without friction." (Source –Business Wire) Brandon Black, Senior Vice President and General Manager at Ivanti, stated, "This partnership is another example of how our 'hands off the host app' approach that is a core tenet of the Ivanti Wavelink's Velocity platform can aid in increasing productivity, accuracy, and safety. Because Velocity interfaces with existing enterprise applications without the need to migrate or modify the host application, there is minimal implementation time." (Source –Business Wire) About Ivanti Ivanti discovers, manages, secures, and services IT assets from cloud to edge. It serves over 40,000 customers, including 96 of Fortune 100. It values all perspectives at Ivanti and works toward a more sustainable future for its partners, customers, staff, and the world. Customers choose Ivanti to discover, manage, secure and service their IT assets from cloud to edge to deliver excellent digital employee experiences and improve the IT and security teams' productivity and efficiency.

Read More

Events