Digital Twins - What and Why...
David Pereira
Future of Work Advisor | Automation Enthusiast | Industry 4.0 Evangelist | Business Developer
The concept of digital twins is nothing new. However, recently, with the uptick in digital transformation projects, organisations have made a quantum leap in what digital twin platforms can actually do for them. Often, business leaders are inundated with information overload, especially regarding digital twins. The concept of digital twins means something different depending on the application.
Lets start with what a digital twin is...
Digital Twins. These virtual replicas of products, processes, systems, and even entire facilities are like your industrious alter ego that never sleeps, never takes vacations, and, most importantly, never complains.
Application #1. Product Digital Twin: Because Two (Digital) Heads Are Better Than One
What It Is: Imagine your product with a secret double life as a virtual superstar, endlessly testing, optimizing, and perfecting itself without all the messy trial and error. A Product Digital Twin is your product’s brainier, digital version that gets the job done before you even think of hitting the assembly line.
Where It Shines:
- Design and Testing: Tired of spending money on prototypes that just don't work? Product twins get it right in the virtual world first.
- Predictive Maintenance: Think of it as your product’s personal trainer—spotting flaws before they turn into serious injuries.
Example: Siemens NX – This is your product’s nerdy best friend, integrating design, engineering, and manufacturing simulation. It’s like a test drive without the pricey fender benders.
Process Mining Magic: By using process mining, Siemens NX analyzes every design tweak and production step. It’s like having a detective uncover every inefficiency and whisper, “Hey, maybe skip that one.”
Application #2. Process Digital Twin: The Workflow Whisperer
What It Is: Ever feel like your processes are running the show? Time to take back control! A Process Digital Twin maps out your workflows, pokes around for inefficiencies, and smooths out the bumps in your operational road. Think of it as GPS for your business operations—but it won’t shame you for taking the wrong turn.
Where It Shines:
Example: BusinessOptix Digital Twin – BusinessOptix dives deep into your processes, optimizing everything from factory floors, to supplier management to customer experience. It’s like Marie Kondo for operations, sparking joy by kicking inefficiencies to the curb.
Process Mining Magic: This enables your digital twin to have a direct integration into your "live data." This in turn enables you to make proactive decision making based on a live data feed.
Application #3. System Digital Twin: The Bigger Picture Guru
What It Is: Got a complex system with a million moving parts? Meet the System Digital Twin, your all-seeing eye that knows how everything fits together. It’s like having a backstage pass to your operation’s rock concert—every component in perfect harmony.
Where It Shines:
- Smart Cities: Coordinating traffic lights, power grids, and public transport like a maestro.
- Aerospace and Defense: Keeping entire aircraft systems in sync and avoiding expensive “oops” moments.
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Example: Ansys Twin Builder – This twin builds virtual versions of complex systems, like your car’s engine or that aircraft you’re boarding. It’s the backstage tech crew ensuring the show runs smoothly.
Process Mining Magic: By layering process mining on top, Ansys Twin Builder doesn’t just simulate—it refines. It takes all that data and finds the best way for your system to sing in perfect pitch.
Application #4. Asset Digital Twin: The Tech that Talks to Your Stuff
What It Is: Think of this as your equipment’s personal diary—only instead of teenage angst, it’s filled with useful insights about performance, wear, and tear. Asset Digital Twins keep an eye on machinery, vehicles, and other assets, so you don’t have to.
Where It Shines:
- Predictive Maintenance: Stop dealing with surprise breakdowns. This twin sees them coming a mile away.
- Energy Management: Making sure your assets don’t gobble more energy than they need.
Example: IBM Maximo – It’s the all-knowing guru of asset management, monitoring every bolt and cog to keep things running smoothly. Maximo’s got your back, and your gear’s too.
Process Mining Magic: With process mining, Maximo becomes the Sherlock Holmes of asset management—solving the mystery of inefficiencies by sifting through data clues.
Application #5. Hybrid Digital Twin: The Multitasking Mastermind
What It Is: Can’t decide on just one twin? Why not all of them? Hybrid Digital Twins are the ultimate multitaskers, blending product, process, and system twins into a unified force for good (and efficiency).
Where It Shines:
- Manufacturing Plants: Getting the entire operation in sync, from assembly line to shipment.
- Healthcare: From patient flow to equipment monitoring, keeping things running smoother than a well-oiled stethoscope.
Example: Dassault Systèmes 3DEXPERIENCE – This platform is the Swiss Army knife of digital twins, handling everything from virtual design to real-world production.
Process Mining Magic: Process mining here is the secret sauce—uncovering hidden inefficiencies, streamlining operations, and making sure your hybrid twin is firing on all cylinders.
Final Thoughts: Embrace Your Digital Doppelgangers
Digital twins are more than just fancy replicas; they’re your backstage pass to smarter, faster, and more efficient operations. Throw in a bit of process mining magic, and these twins become true overachievers—finding every hidden inefficiency and turning it into a win.
So, whether you’re trying to optimize a product, a process, or an entire facility, it’s time to let these digital doppelgangers do the heavy lifting. After all, why settle for just one of you when you can have the digital version too?