Companies are constantly on the lookout for ways to fine-tune their operations, deliver top-notch customer service, and stay one step ahead of trends, all to spot potential threats or opportunities. That’s where digital twins come into play—they’re like a supercharged tool that can tackle these aspects head-on.

Around 50% of the time, digital twinning is primarily employed to enhance operational performance and manage quality control. Additionally, it is utilized for systems planning, which accounts for approximately 44% of its application.

In Layman’s language…

A digital twin is a virtual model designed to accurately reflect a physical object. The object being studied—for example, a wind turbine—is outfitted with various sensors related to vital areas of functionality. These sensors produce data about different aspects of the physical object’s performance, such as energy output, temperature, weather conditions, and more. This data is then relayed to a processing system and applied to the digital copy.

Once informed with such data, the virtual model can be used to run simulations, study performance issues, and generate possible improvements, all to generate valuable insights—which can then be applied back to the original physical object.

In recent years, the concept of digital twins has gained significant attention across various industries like manufacturing, healthcare, and transportation.

In this article, we will delve into the benefits of using digital twins and explore how they are transforming industries worldwide. But first, let’s understand the concept of digital twins.

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What are Digital Twins?

Digital twins are virtual replicas of physical objects, processes, or systems that simulate their behavior and characteristics in real-time.

They serve as digital counterparts, capturing data from sensors and devices embedded in their physical counterparts, allowing for monitoring, analysis, and optimization. These digital replicas enable us to gain valuable insights, make informed decisions, and drive innovation across various industries.

With the proliferation of Internet of Things (IoT) devices, digital twins have gained significant traction. According to Gartner, by 2023, it is estimated that there will be over 30 billion connected devices globally, providing a wealth of data for digital twins to leverage. This exponential growth presents immense opportunities for industries to harness the power of digital twins.

Benefits of Digitial Twins

• In manufacturing, they facilitate product design optimization, allowing engineers to simulate different scenarios and test various configurations virtually. This reduces the need for physical prototypes, saving time and costs.
• They enable predictive maintenance, where anomalies in asset performance can be detected and addressed proactively.
• According to a study by Deloitte, predictive maintenance driven by digital twins can reduce maintenance costs by up to 40% and increase equipment uptime by up to 20%.
• In smart cities, digital twins enable urban planners to simulate and optimize infrastructure projects, traffic flows, and energy usage. This helps in improving sustainability and resource efficiency.
• Siemens reported that by leveraging digital twins, Dubai reduced energy consumption by 20% and water consumption by 30%.

Enhanced Design and Simulation Capabilities

Digital twins offer a remarkable advantage by providing engineers and designers with an advanced platform for designing and simulating products, processes, and systems. By creating a virtual replica of a physical entity, they enable testing and optimization of various scenarios before the actual implementation takes place. This capability has a significant impact on design efficiency, leading to improved product performance and functionality.

A study by PTC reveals that companies that utilize digital twins in their design processes can reduce overall development time by up to 20%. This time-saving is achieved by minimizing the need for physical prototyping and streamlining design iterations within the virtual environment.

Through the identification and resolution of potential issues within the digital twin, engineers can proactively make necessary adjustments in the early stages of the design phase. This proactive approach effectively minimizes the need for costly rework during the production process.

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With a virtual playground for creativity, engineers and designers can explore unconventional ideas and push the boundaries of design. This freedom to experiment results in breakthrough solutions and fosters a culture of innovation within organizations.

Lenley Hensarling, Chief Product Officer, Aerospike, explains how massive amounts of data about environments, devices, and experiences over time drive the evolution of models.

“These models can be for specific pieces of machinery, but they may also be for a more holistic view of the machinery in a process within an environment. This implies retaining not just data from the instrumentation of the equipment but also data in the environment — and of the other equipment that may be involved. Devices interact with each other. New advances in data management and the availability of vast amounts of storage in the cloud have opened up new opportunities for more complex and higher fidelity models, not just about a given piece of equipment, but about the environment, the processes the equipment is involved in, and how the equipment interacts with other systems.”

Enhanced Efficiency and Sustainability in Transportation

A November 2022 report by the world road transport body IRU revealed that there could be two million unfilled driving positions in Europe by 2026 (already now there are around half a million unfilled positions in Europe, including about 60.000 in the UK).

Adding a mere 18 minutes of driving time can eradicate the capacity crunch – according to scientists at the MIT Center for Transportation and Logistics. This claim was based on research in the US but pointed out that the same principle is likely to apply in Europe.”

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To understand how digital twins were aiding sustainability, we got in touch with Jaspreet Singh, Senior Product Manager, Trimble MAPS. She explained how Trimble utilized digital twins in the transport sector to enhance efficiency and accuracy in operations.

 “Digital Twins will help provide more accurate ETAs to fleets, allowing them to have enhanced efficiency in their operations. The enhanced and accurate ETA will allow for better load planning for future loads. The goal is to provide an efficient workflow to back office individuals. Today, our understanding is that fleet/driver manager spend a tremendous amount of time digging through loads and trucks in order to understand the ones that require their attention due to exceptions (ETA, unplanned stops, weather). Digital twin technology will improve their efficiency by alerting on the ones that need attention.”

While discussing how digital twins have contributed to reducing environmental impact and promoting sustainability in the transportation industry, she says,

“Providing optimized routes / mileage calculation will ensure the least number of miles, which obviously has a positive environmental impact. Since the digital twin is taking into account live GPS pings of the truck, it will alert on situations where the driver is going off route and adding unnecessary miles. This allows the ability to bring the driver back on track asap.”

Transporeon, a Trimble company, uses digital twins in its Carbon Visibility – a tool for accurate and transparent measurement, reporting, reducing, and benchmarking greenhouse gas emissions from transport.

“In particular, the tool uses the digital twin technology for calculating GHG emissions based on primary data for a ‘shipper-carrier-corridor’ combination, even if the carrier does not share primary data with that shipper. This method involves taking data directly from a truck and including each truck, each route, as well as such driving data as acceleration and braking data.”

Serge Schamschula, Head of Ecosystem for Transporeon, a Trimble Company, further added, 

“Using digital twins, Transporeon also develops algorithms that predict fuel consumption and consequent CO2 emissions. The technology can be used to forecast the effect of future transports conducted by incumbents and new suppliers on the entire GHG emission footprint, in order to make data-driven decisions for contracting and tendering, calculate the carbon footprint of any future procurement scenario, and allow benchmarking alternative supply chain networks against a science-based reduction target.”

Improved Monitoring and Predictive Maintenance

Digital twins offer significant advantages in terms of monitoring and predictive maintenance capabilities. By integrating sensors and IoT devices with the digital twin, businesses can capture real-time data about the performance, condition, and usage patterns of their assets. This wealth of information allows for proactive maintenance strategies and optimization of asset utilization.

Hensarling, while explaining the crucial role industrial IoT sensors play in enhancing industrial design, says, 

“Industrial IoT sensors provide the real-world feedback that can be shared with the digital twin to uncover usage, reliability, and performance metrics that enhance future iterations of the industrial design. Then, the IoT sensor data aggregated at the edge can be fed into AI and machine learning engines to optimize insights for the digital twin and enable predictive planning, design, production, and maintenance.”

This instrumentation leads to an understanding of the current situation of individual devices/equipment. When we add data about the external environment the equipment is in, we have a more nuanced idea of why things are happening.

He further adds,

“How does the equipment operate in hot environments, humid environments, or where there is a lot of dust? Our models of the environment are just as important as the model of the equipment, and together they form a model of the equipment in a given environment. That leads to a new understanding of maintenance cycles that differ by where the equipment is deployed as well as the characteristics of the equipment in that environment.”

By altering models with variables that represent modifications to the equipment, experiments can be run in software rather than in the more costly real environment. What is the effect of a better air filter? It’s more costly, but if it allows the meantime to fail to go up, then there may be significant savings overall.

McKinsey reports that implementing predictive maintenance through digital twins can result in maintenance cost reductions of up to 20% and downtime reductions of up to 50%.

Digital twins leverage data collected from embedded sensors within physical assets to analyze and detect anomalies and patterns. These insights serve as early indicators of potential equipment failures or inefficiencies.

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They further help the maintenance teams to take preventive actions before major breakdowns occur, reducing unplanned downtime and any associated costs.

Furthermore, the insights provided by digital twins can be leveraged to optimize operational processes and increase energy efficiency. By monitoring asset performance and usage patterns, organizations can identify areas for improvement and implement changes that enhance overall system efficiency. Organizations can transform their maintenance practices and achieve significant improvements in both costs and operational performance.

Srini Vasan, CTO, of Game of Silks, elaborates on the role of AI in improving the predictive capabilities of digital twins,

“AI can act as the driving force behind the predictive capabilities of digital twins. These virtual replicas of physical systems—whether they’re power grids, railway networks, healthcare systems, water treatment plants, or oil rigs—generate vast amounts of data. AI, with its analytical prowess, sifts through this data, identifying patterns and anomalies that could indicate potential issues. This predictive ability can foresee when a component might fail or when a machine might need servicing, transforming maintenance from a reactive task to a proactive strategy. Downtime is minimized, operations are optimized, and reliability is enhanced.

Real-time Simulation and Control

Digital twins empower operators and engineers with real-time simulation and control capabilities, enabling them to make informed decisions and optimize complex systems. By integrating data from various sources and simulating real-world scenarios, digital twins provide a virtual window into systems, allowing for prompt identification of bottlenecks, workflow optimization, and agile responses to changing conditions.

Digital Twins in Energy & Utilities Sector – Fueling Efficiency, Cost Reduction, and Grid Stability

MarketsandMarkets report that the digital twin market in the energy and utilities sector is expected to grow at a compound annual growth rate (CAGR) of 36.7% from 2020 to 2025. Digital twins enable operators to optimize energy distribution, manage load effectively, and ensure efficient utilization of resources. This leads to improved energy efficiency, reduced costs, and enhanced grid stability.

Digital Twins in Healthcare – Transforming Patient Monitoring and Personalized Treatment 

Patient monitoring and personalized treatment plans are the highlights of digital twins in the healthcare sector. With the integration of real-time physiological data with predictive models, digital twins aid in monitoring patient health, identifying potential risks, and optimizing treatment strategies. This proactive approach enables healthcare professionals to deliver personalized care, improve patient outcomes, and enhance safety.

Srini, while talking about the role of digital twins in healthcare, further explained, 

“In the healthcare industry, digital twins are being used to improve the diagnosis and treatment of diseases. For example, the Mayo Clinic is using digital twins to simulate the behavior of the human heart, which helps doctors to better understand and treat heart disease. In the energy industry, digital twins are being used to improve the efficiency and reliability of power plants. For example, GE is using digital twins to monitor the performance of its wind turbines, which helps to identify potential problems and prevent outages.”

Digital twins grant us a virtual portal to our systems, empowering us to make instantaneous decisions that directly influence productivity, safety, and customer satisfaction. The ability to simulate and control systems in real time enables organizations to respond swiftly to changing circumstances, ensuring optimal performance and customer satisfaction.

Stephen DeAngelis, while speaking about the role of IoT, energy equipment, and software products, said, 

As the world continues to experience significant macroeconomic disruptions, businesses are adopting advanced AI solutions to help navigate market uncertainty and changing consumer behavior. Digital twins have emerged as a component of a solution set that allows organizations to take real-world data from the marketplace, machines and information systems and produce simulations about how they will perform. However, their downfall is that they are not dynamic to the point where they go beyond the ability to model “today’s” business environment. To be fully dynamic, digital twins need to be imbued with the capability to reason, perform optimization, and make informed recommendations that present valid alternative scenarios to activate to obtain business objectives, drive competitiveness and resiliency.

He further added,

The most advanced enterprise decision-making solutions on the market today, which leverage a unique combination of human-like reasoning and generative AI, glass-box machine learning, and real-world optimization, are capable of decoding and navigating complexity in an increasingly uncertain and changing competitive business landscape. They allow businesses to understand how human experience factors (e.g., changing consumer preferences, alternative food preferences, etc.), socio-economic drivers (e.g., climate change, pandemic, political risk, etc.) and actions from participants in the environment (e.g., a competitor runs a promotion, or a supplier increases its prices) impact the landscape to drive enterprise-level competitiveness and resiliency.

Digital in Supply Chain

Srini also spoke about how artificial intelligence can enhance the accuracy and reliability of real-time data analysis within digital twin frameworks. While speaking about the implications, and optimizing decision-making processes in areas such as supply chain management and logistics, he added,

“AI’s role in real-time data analysis allows for the instantaneous processing and analysis of large volumes of data, providing invaluable insights that can inform decision-making in the moment. In industries like supply chain management, logistics, and e-commerce, AI-powered digital twins can predict the impact of a disruption or suggest optimal routes for delivery based on real-time traffic data and weather conditions. They can also analyze real-time data on inventory levels, order volumes, and delivery schedules to predict potential bottlenecks and suggest ways to optimize operations. The result? Increased efficiency, reduced costs, and improved resilience. Much of this system improvement has been accomplished by AI in various ways for years, and digital twins can serve as the next evolutionary step forward.”

Accelerated Innovation and Prototyping

They are a pivotal factor in expediting innovation and prototyping procedures by facilitating virtual testing and experimentation. Through the simulation of diverse design configurations and scenarios, businesses can streamline the development and validation of novel products and services. This iterative approach not only reduces time-to-market and mitigates risks but also fosters a culture of continuous improvement.

According to a study conducted by Deloitte, organizations that adopt digital twins in their innovation processes experience a 30% reduction in time-to-market for new products and services. Companies can rapidly iterate and fine-tune their designs within the virtual environment, allowing them to identify and resolve potential issues before physical prototyping. This shortened product development cycle not only enables faster market entry but also provides a competitive advantage in dynamic industries.

They also foster collaboration and knowledge sharing among cross-functional teams. By providing a shared platform for designers, engineers, and domain experts, digital twins break down traditional silos and encourage open communication. This collaborative environment enhances creativity, drives breakthrough solutions, and promotes a culture of continuous learning within organizations.

Optimized Resource Management

Digital twins can directly impact and optimize resource management and minimize waste. These advanced virtual models enable the simulation and analysis of intricate systems. In the realm of manufacturing, digital twins prove invaluable in simulating production processes, pinpointing inefficiencies, and optimizing material and energy consumption. This approach ultimately leads to cost reduction, enhanced sustainability, and a reduced environmental footprint

According to a report by McKinsey, companies that leverage digital twins in manufacturing processes can achieve up to a 20% reduction in material costs and up to a 15% increase in production efficiency.

Through the power of simulation, manufacturers can delve into production scenarios and uncover areas for improvement, leading to optimized resource utilization, waste reduction, and heightened operational efficiency. This dynamic approach not only yields substantial cost savings but also aligns with environmental goals, fostering sustainable practices. It’s a win-win situation where innovation meets sustainability on the factory floor.

Digital Twins in Urban Planning

Digital twins are also transforming urban planning and the development of smart cities. By creating virtual replicas of cities, urban planners can simulate the impact of various infrastructure projects, optimize traffic flows, and enhance energy efficiency. This holistic approach to resource management improves the quality of life for residents while minimizing resource waste.

A study conducted by the European Commission estimates that the use of digital twins in urban planning and management can lead to energy savings of up to 30%, reduce greenhouse gas emissions by up to 25%, and decrease traffic congestion by up to 20%.

City planners can embark on a data-driven journey, making decisions that not only amplify efficiency but also champion sustainability. These well-informed choices lead to tangible benefits, positively impacting both the environment and the entire community. Get ready to witness the transformation as cities embrace innovation and pave the way for a brighter, more sustainable future.

Digital twins offer a holistic perspective on resource utilization, empowering us to make informed decisions based on data. This data-driven approach enhances efficiency and promotes sustainability.

Use Cases of Digital Twins: Revolutionizing Industries with Virtual Replicas

General Electric (GE)

Their digital twins work wonders on industrial equipment like gas turbines and jet engines. They’re like the ultimate wingman, enabling predictive maintenance, real-time monitoring, and even simulation-based testing. The result? A remarkable boost in operational efficiency and a significant drop in pesky downtime.

Siemens

Siemens leverages digital twins to enhance the design and manufacturing processes for its industrial products. With virtual replicas of products and production lines, Siemens optimizes workflows, simulates scenarios, and improves quality control, leading to accelerated innovation and improved product performance.

Microsoft

Microsoft’s digital twins enable the tech giant to encourage sustainability. These digital twins offer a front-row seat to real-time monitoring of energy consumption, space utilization, and even predictive maintenance. With this dynamic insight, Microsoft becomes the master of resource allocation, crafting incredibly sustainable working environments that leave a positive impact. It’s a captivating fusion of technology and environmental consciousness that sets the stage for a greener future.

ABB

ABB utilizes digital twins to optimize the operations of power grids and industrial automation systems. The digital twins take energy distribution optimization to a whole new level, delivering impeccable reliability, slashing downtime, and revolutionizing grid management.

Ford

Ford leverages digital twins to enhance the design and manufacturing of its vehicles. By creating virtual replicas of car components and assembly lines, Ford can simulate different scenarios, optimize production processes, and improve product quality, leading to faster time-to-market and improved customer satisfaction.

Honeywell

Honeywell utilizes digital twins to optimize the performance of its industrial processes, such as refining and chemical production. With the help of virtual replicas, Honeywell can monitor real-time data, identify inefficiencies, and optimize production parameters, resulting in increased operational efficiency and reduced costs.

Airbus

Airbus utilizes digital twins to enhance aircraft design, manufacturing, and maintenance processes. These digital twins enable Airbus to simulate and optimize various aircraft configurations, monitor performance data in real time, and predict maintenance needs, leading to improved safety, fuel efficiency, and operational reliability.

Johnson Controls

With the help of digital twins, they unlock the true potential of building systems like HVAC, lighting, and security. By crafting virtual replicas of buildings, Johnson Controls gains the power to monitor real-time data, fine-tune energy usage, and elevate occupant comfort to new heights. Brace yourself for the impressive results: energy savings, heightened sustainability, and a remarkable boost in facility management capabilities. Johnson Controls is rewriting the playbook, creating a world where buildings seamlessly blend efficiency, sustainability, and optimal occupant experiences.

IBM

IBM utilizes digital twins to optimize the operations of complex supply chain networks. By creating digital replicas of supply chain processes, IBM can monitor inventory levels, track shipments, and simulate different scenarios, enabling more efficient logistics planning, reduced costs, and improved customer satisfaction.

PTC

PTC provides digital twin solutions for a range of industries, including manufacturing, healthcare, and transportation. Their digital twin technology enables companies to monitor and optimize the performance of assets, improve product design, and enhance operational efficiency, resulting in improved productivity, cost savings, and better customer experiences.

These are just a few examples of how various industries are leveraging digital twins to drive innovation, improve operational efficiency, and optimize their processes. The potential of digital twins is vast, and their applications are expanding rapidly across different sectors.

Conclusion

In a world where technology is constantly evolving, digital twins have emerged as a game-changer with the potential to revolutionize industries on a global scale. Their significance cannot be overstated. From streamlining design processes to predicting and preventing maintenance issues, digital twins offer a myriad of benefits that have a tangible impact on businesses.

Srini explains that the increasing complexity of interconnected systems presents both challenges and opportunities when it comes to leveraging AI-powered digital twins. The challenge lies in managing the large volume of data generated by these systems; however, the opportunities are too great to ignore. AI-powered digital twins can provide a holistic view of large-scale environments. At the same time AI-powered digital twins are susceptible to unintentional bias (or malicious data poisoning) and Security threats since digital twins can contain sensitive data, and AI systems can be vulnerable to cyberattacks. This could lead to the theft of data or the disruption of operations.

By harnessing the power of digital twins, organizations can gain a competitive edge in their respective markets. They enable businesses to optimize their operations, make data-driven decisions, and drive innovation at an accelerated pace. The ability to have a comprehensive view of resources and processes empowers companies to identify inefficiencies, enhance productivity, and achieve operational excellence.

Furthermore, digital twins pave the way for real-time control, enabling businesses to respond swiftly to changing conditions and make adjustments as needed. This level of agility and adaptability is crucial in today’s dynamic and interconnected world.

Importantly, digital twins also contribute to sustainability efforts. By providing a deep understanding of resource utilization and enabling data-driven decision-making, they help businesses optimize their energy consumption, reduce waste, and minimize their environmental footprint.

In conclusion, the transformative potential of digital twins is vast. They offer a unique opportunity for businesses to unlock new possibilities, enhance operational efficiency, and drive sustainable growth. Embracing digital twins is not just a technological choice; it is a strategic imperative for organizations that seek to thrive in an increasingly complex and interconnected landscape.