A technology originally pioneered by NASA for its Apollo missions back in the 1960s is now taking center stage in the manufacturing industry. During a time of labor shortages, supply chain issues and rising material costs, so-called "digital twins" give manufacturers the ability to dramatically improve the way they do business, from enhancing factory design and streamlining operations to informing strategic decision-making.

The National Institute of Standards and Technology (NIST) estimates that the potential overall impact of the adoption of digital twins in the manufacturing industry is likely in the low tens of billions of dollars.

Digital twins defined

Digital twins are virtual representations of a physical object, process or system. According to the NIST, the technology is more accurate and flexible than other types of modeling. That's because digital twins are continually updated with real-time production, inventory and demand data obtained from your manufacturing execution system, Internet of Things devices and inventory databases. Armed with this data, digital twins use simulation and machine learning to guide and even automate decision-making.

For example, a manufacturer could create digital twins of specific production processes, equipment or components — or of an entire factory's operations. With closed-loop feedback, it can use a digital twin for real-time monitoring that facilitates the optimization of workflows and machine use. A digital twin can also be deployed to validate new or revised processes before implementation, identify bottlenecks and improve production planning.

Putting the technology to work

Digital twins can assist with everything from process tweaks to original product design and development — without causing costly real-world disruptions or requiring the development of as many physical prototypes. The technology enables manufacturers to explore "what-if" scenarios that reveal the likely outcomes of changes in processes, materials, layout or scheduling. Digital twins can reduce the time to market for new products, improve quality control through root cause analysis and enhance the end-user experience.

The technology also leverages vast amounts of gathered data for predictive maintenance, which may preempt downtime and, in turn, boost production numbers. When problems arise, it allows for troubleshooting methods not easily performed on physical equipment, expediting resolutions.

But the benefits aren't restricted to products and processes. Digital twins can play a critical role in workforce training, too. Employees can undergo training in a virtual environment, without ever touching the actual physical equipment, reducing the risk of harm to both them and the equipment.

Challenges to implementation

As is the case with so many data-driven technological improvements, the old saying "garbage in, garbage out" rings true with digital twins. The integrity of the data employed by a digital twin is critical, and your data ecosystem might not be up to snuff. It's not uncommon for a manufacturing company's essential data to be fragmented, scattered and difficult to connect in a coherent manner. The data must be "cleaned" and structured both initially and on an ongoing basis, which may be the biggest barrier for smaller manufacturers with older equipment.

The collection and maintenance of data is just one aspect of the digital twin experience that calls for a level of expertise many manufacturers typically lack in-house. The development of the technology generally requires a cross-functional team, with representatives from the manufacturing side (for example, floor managers) along with data engineers and IT architects. For this reason, third-party assistance is often necessary.

Even with such support, the development of a custom-built digital twin isn't a quick process. Typically, two to three months is the bare minimum, and, depending on the complexity, it could take more than a year.

The time and monetary investments can be daunting. The good news is that off-the-shelf software packages are available, so you can test the waters before diving in wholeheartedly.

Worth considering

Digital twin technology can be costly and isn't necessarily worth the investment for simpler manufacturing processes. But it's not some futuristic dream — digital twins already are making a significant impact for some manufacturers, giving them a valuable competitive edge. Now's the time to begin exploring whether this technology could help your manufacturing company.