How Smart Manufacturing Is Powered by Digital Twin Technology?

Bhagyashri Kambale | December 08, 2021 | 540 views
SMART_MANUFACTURING
A digital twin is a virtual model of an object or system that comprises its lifecycle. It is updated with real-time data and aids decision-making through simulation, machine learning, and reasoning for the production system.

IoT sensor data from the original object is used to create a digital twin of the system. This cloud-connected data allows engineers to monitor systems and model system dynamics in real-time.

Modifications can be tested on the digital twin before making changes to the original system.

Considering that digital twins are supposed to replicate a product's complete lifecycle and are used throughout the production process, it's not unexpected that digital twins have become prevalent in all stages of manufacturing.

“More than a blueprint or schematic, a digital twin combines a real-time simulation of system dynamics with a set of executive controls,”

– Dr. Daniel Araya, consultant and advisor with a special interest in artificial intelligence, technology policy, and governance

Companies will increasingly embrace digital twins to boost productivity and decrease expenses. As per recent research by Research and Markets, nearly 36% of executives across industries recognize the benefits of digital twinning, with half planning to implement it by 2028.So how does this digital twin technology benefit modern manufacturing? Let's have a look.


How the Digital Twin Drives Smart Manufacturing

Digital twins in manufacturing are used to replicate production systems. Manufacturers can develop virtual representations of real-world products, equipment, processes, or systems using data from sensors connected to machines, tools, and other devices.
In manufacturing, such simulations assist in monitoring and adapting equipment performance in real-time. With machine learning techniques, digital twins can predict future events and anticipate potential difficulties.

For maintenance, digital twins allow for quick detection of any problems. They collect real-time system data, prior failure data, and relevant maintenance data. The technique employs machine learning and artificial intelligence to predict maintenance requirements. Using this data, companies can avoid production downtime.


Digital Twin and Artificial Intelligence (AI) in manufacturing

Using digital twins and AI in production can enhance uptime by predicting potential failures and keeping equipment working smoothly. In addition, there are significant cost savings in the planning and design process as digital twins and AI can be used to replicate a specific scenario.

Maintenance is another area that has seen significant progress with the use of digital twin manufacturing. A Digital Twin powered by AI can predict when a piece of equipment will fail, allowing you to arrange predictive maintenance that is not simply taking information from OEM manuals but can significantly cut maintenance expenses along with reducing downtime.

Using the digital twin, it is feasible to train virtual workers in high-risk functions, similar to how pilots are trained using flight simulators. It also frees up highly skilled workers to upgrade the plant and streamline operations.


General Electric Created the Most Advanced Digital Twin

General Electric Company (GE) is a multinational business based in Boston that was founded in 1892. It has developed the world's most advanced digital twin, which blends analytic models for power plant components that monitor asset health, wear, and performance with KPIs (Key Performance Indicators) determined by the customer and the organization's objectives. The Digital Twin is powered by PredixTM, an industrial platform built to manage huge amounts of data and run analytic algorithms. General Electric Company provides extra "control knobs" or "dimensionality" that can be utilized to improve the operation of the system or asset modeled with GE Digital Twin.


Final Words

Given the numerous advantages of digital twin manufacturing, the potential for digital twins to be used in manufacturing is virtually endless in the near future. There will be a slew of new advancements in the field of digital twin manufacturing. As a result, digital twins are continually acquiring new skills and capabilities. The ultimate goal of all of these enhancements is to create the insights necessary to improve products and streamline processes in the future.


FAQ


What is a digital twin in manufacturing?

The digital twins could be used to monitor and enhance a production line or perhaps the whole manufacturing process, from product design to production.


How digital twin benefit manufacturers?

Using digital twins to represent products and manufacturing processes, manufacturers can save assembly, installation, and validation time and costs.


What is a digital thread?

A digital twin is a realistic version of a product or system that replicates a company's equipment, controls, workflows, and systems. The digital thread, on the other hand, records a product's life cycle from creation to dissolution.

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