As manufacturers continue to build their Industrial Internet of Things (IIoT) infrastructure, digital twins should clearly be a part of it. Because digital twins represent a highly accurate and detailed virtual version of a factory or its assets, the technology can provide decision-makers with greater visibility than ever before.
Let's take a closer look at some of the specific benefits that digital twins bring to manufacturing teams.
Improve efficiency and reduce costs during factory construction.
When Beijing hosted the 2008 Olympics, organizers and officials planned a host of measures to improve air quality. These efforts continue today, and when China hosts the Olympics again in 2022, participants will have the opportunity to assess their impact. One such initiative was the relocation of a large portion of steel production capacity to provinces adjacent to the capital.
Xuanhua Steel Plant is one of the factories required to relocate. The plan to relocate this 89-year-old facility includes creating a digital twin. This model will help track what's happening inside the plant while efforts are underway to get it fully operational in its new location. The digital twin can display design progress, construction progress within the plant, and delivery times, among other things.
According to Machine Design, relying on digital factories has reduced commissioning costs by 75%. This approach has also shortened the design cycle by 35 days. The benefits should extend beyond construction; for example, those familiar with digital twins believe that optimizing shot blasting machines can save 60-70% on operating energy consumption.
The factory covers 534 hectares. Furthermore, its production lines generate hundreds of megabytes of data per second. Creating such a massive digital twin to handle such a vast amount of data is no easy task. However, this example demonstrates how it can be rewarding both during and after construction.
Help employees make decisions and improve processes
Digital twins can also support Internet of Things (IoT) infrastructure, providing employees with the real-time data they need to make smarter, more confident decisions. Mars, a multinational food and pet supplies brand, is undergoing a cloud-first digital upgrade to enhance how people use connected technologies.
The brand's leader selected Microsoft Azure Digital Twin to support the company's existing Industrial IoT technologies, as well as any technologies that may be deployed in the future. "This will transform our relationship with consumers, delivering hyper-relevant consumer experiences, including content and media, and meeting the needs and expectations at every touchpoint in the consumer journey," said Sandeep Dadlani, Mars' Chief Digital Officer, speaking about the partnership.
One goal of using digital twins is to help field employees make real-time decisions based on what the technology displays. This approach can also enhance existing processes. Standardizing how workers perform their duties can reduce injuries, while also reducing inefficiencies and errors. Digital twins can even solve bottlenecks caused by having too many workers in one place at a given time.
Reduce maintenance costs while improving customer service coverage
Many company executives believe that implementing digital twins in IoT infrastructure can minimize the costs associated with unexpected equipment downtime. Equipment downtime is particularly problematic in manufacturing, where even a few hours of downtime can result in losses of tens of thousands of dollars, depending on the product and its overall demand.
The use of IoT sensors is already commonplace when proactive maintenance becomes a priority. In one example, an automotive parts manufacturer wanted to curb the failure of fans in its brazing furnace, as each fan took several days to repair.
The company's data scientists examined the information from the sensors and determined that a shutdown would soon occur if maintenance personnel did not address the issue. More specifically, they warned that the fan had only 58 hours of use left and needed to be replaced immediately. The maintenance team was initially skeptical of this claim; however, when they removed the fan, they found the blades were broken.
Digital twins can also be used for maintenance purposes, sparking customer interest. For example, INDEX Group offers its iXworld platform, which provides real-time data on machine performance and condition. This is a significant selling point for customers tired of unexpected equipment failures. Similarly, Mitsubishi Electric's digital twin doubles as a customer service portal, allowing users to submit issues and order replacement parts.
Daimler leaders anticipate that digital twins will establish a common thread of data at every stage of the car's journey, from initial design to delivery to the end customer. The company has already implemented this approach in Mercedes-Benz models. According to Industry Week, Mercedes-Benz's digital twins can remotely update the car's software, reducing the likelihood of problems with outdated versions. It can also reveal driver usage habits, allowing the company to recommend relevant products and services.
Improving productivity in challenging environments
The COVID-19 pandemic has presented significant challenges for manufacturers worldwide. Unfortunately, the pandemic is not over yet. Even though vaccines are readily available in many countries, it remains necessary to adhere to measures such as social distancing. Research indicates that some new variants are more transmissible than the original virus and more likely to evade vaccine protection.
In the UK, a survey shows that supply chain issues have hampered manufacturers' efforts to recover from the COVID-19 recession. One analysis shows that the growth rate in August 2021 was the lowest in six months. However, because digital twins offer a better understanding of what's happening in factories, they can help leaders anticipate problems more quickly, giving them more time to develop effective strategies to address them.
This tool can also help in adapting real-world processes to more safely adapt to the new normal brought about by COVID-19. Similarly, it can help factory managers adjust protocols to address any other challenges that may arise in the future. For example, digital twins can demonstrate how new processes work before factory teams implement them.
Digital twins can also accelerate vaccine production, a perpetually important concern. GlaxoSmithKline recently completed a digital twin trial related to the production of adjuvant particles used in vaccines.
It provides companies with instant digital feedback on their processes. This advantage improves processes. It can also limit variability that could slow production and help companies by minimizing the risks of starting up and operating new facilities.
Assess needs before adopting a digital twin.
These examples illustrate the many reasons why manufacturing professionals incorporate digital twins as part of their existing IoT infrastructure. Doing so can yield significant rewards, but success is not guaranteed.
Manufacturers should consider their most pressing needs and obstacles. From there, they can think about how digital twin technology can help, and whether certain tools on the market have the functionality and capabilities to meet their expectations.
When implementing digital twins, it's also helpful to look at what other manufacturing leaders are doing. This industry was one of the first to use these tools, and as adoption has increased, the wider applications of these tools have become apparent.
