Building a digital twin: Benefits and challenges

Digital twins are on the rise, and the momentum isn’t slowing down anytime soon. Back in 2023, analysts valued the digital twin industry at $12.91 billion globally. Fast forward to 2032, and Fortune predicts it’ll skyrocket from $17.73 billion in 2024 to an incredible $259.32 billion [1]. That’s some serious growth!

Are you looking to adopt digital twins on your factory floor? If so, let’s explore why this technology is gaining traction and the benefits and challenges it brings to the table.

Digital twin technology is not a new concept. Manufacturers have created 3D renderings of computer-aided design (CAD) models for years, for asset management and prototyping. However, advances in the internet of things (IoT), data analytics, and cloud computing are making digital twins more accessible and affordable. This technology offers significant benefits for manufacturers, including improved efficiency, enhanced decision-making, and predictive maintenance.  

What is a digital twin?

A digital twin is a virtual replica of a real-world asset, such as a building, product, or system. It uses real-time data from sensors to provide an accurate representation of the asset's condition and performance. Key parts of a digital twin include:

• Sensors: They collect data from the physical asset.
• Data analytics: Process and interpret sensor data.
• Visualisation tools: Create a visual representation of the asset.

Benefits of digital twins

1. Improved efficiency

One of the benefits of digital twins is that they have the potential to greatly improve efficiency across many sectors. Digital twin technology can identify anomalies and predict possible failures by continuously monitoring the performance of physical assets. This enables for proactive maintenance and, therefore, minimises downtime. This predictive ability allows companies to optimally schedule maintenance tasks, reducing disruptions and increasing asset lifespans.

Beyond maintenance, digital twin technology can also be used to model and optimise processes, allowing inefficiencies and bottlenecks to be found. Organisations can test different scenarios, make data-driven decisions and fine-tune operations to lower costs and boost productivity. This iterative approach allows for continuous improvement and adaptation to changing circumstances.

Another advantage of digital twins is their role in validating designs before physical prototypes are created. Designers have the ability to identify and address issues early on in the development process. They achieve this by simulating various conditions and conducting tests to uncover potential weaknesses.

This helps reduce the need for costly redesigns and speeds up the time to bring a product to market. This approach not only saves time and resources but also ensures that products meet the desired performance and quality standards.

2. Enhanced decision-making with data-driven insights

Digital twins simulate conditions including pressure, temperature, and vibration. It also incorporates the operational status of the device, whether it is online or offline.

But it doesn’t stop there. A digital twin is able to capture the device's context. This includes information such as its location within the facility and its relationship to other devices or systems. This broader perspective helps manufacturers better understand the bigger picture.

The magic lies in tailoring the data to your goals. For instance, if the business aims to enhance product quality and customer service, they can incorporate data from the sales and marketing teams. You can use this data to simulate how a new product will create fresh opportunities.

Manufacturers can greatly enhance maintenance by incorporating data about a machine. This includes product details, technical specifications, and warranty status. Using a digital twin allows manufacturers to make informed decisions and optimise their maintenance processes.

Engineers can tailor repairs and maintenance to the asset's real use by analysing data and information gathered by the twin. With this method, you won't have to estimate maintenance needs based on the asset's lifespan. By keeping a closer eye on the health of their machines, plant managers can reduce unplanned downtime. This gives them plenty of time to find a replacement before the system fails, allowing them to keep operations running smoothly.

Challenges of digital twins

1. The cost of building a digital twin

For smaller manufacturers, the cost of adopting digital twins can be a significant hurdle. These technologies often require modern IT infrastructure, which not all businesses are equipped to afford.

To avoid falling behind, smaller manufacturers can adopt a gradual approach, scaling their use of digital twins over time.

For example, a company might begin by creating a digital twin for a single asset component, tracking its performance to identify issues or optimise operations. Once the benefits are clear, they can expand by adding more models, eventually creating a comprehensive twin that monitors entire machines or systems.

By taking incremental steps, smaller manufacturers can gradually unlock the potential of digital twins without overextending their resources.

2. The risk of security breaches 

When building a digital twin, it is vital that firms prioritise cybersecurity. This is because the digital twin stores sensitive data that could potentially be exploited to cause harm to the business.

Manufacturers should decide who will have access to the simulation, ensuring that only the necessary people can gain information or control of the asset. Considering cybersecurity during the design phase and clearly managing the type of information collected, where it is stored and who has access to it will reduce the risk of security breaches once the twin is implemented.

Conclusion

The use of digital twins has huge potential for improving business results. By following the steps outlined in this guide and addressing the challenges, manufacturers can harness the power of this technology to drive innovation and efficiency.

As you explore digital twin initiatives, having a reliable partner to source critical industrial components is essential. At EU Automation we support businesses around the globe by sourcing and delivering critical industrial parts, our global reach and industry expertise help manufacturers confidently embrace next-generation technologies—like digital twins—without risking downtime or delays.

Citations:

[1] https://www.fortunebusinessinsights.com/digital-twin-market-106246.