BimScaler Blog – Digital twins in manufacturing are basically virtual copies of physical assets, processes, or systems that mirror their real-world counterparts in real time.
These digital copies let manufacturers test out, predict, and make their operations better and more cost-effective.
The concept is really taking off in Australia, where new tech and research are driving its adoption across industries like aerospace, mining, and urban planning.
So, get ready to break down the future of manufacturing here.
Applications of Digital Twins in Manufacturing
Design and Development
In the design and development phase, digital twins help engineers to create and test virtual prototypes.
This means you don’t need to make as many physical prototypes, saving you time and resources.
In their paper “Digital Twin based Smart Manufacturing; From Design to Simulation and Optimization Schema,” Mohsen Ebnia, Seyed Mojtaba Hosseini Bamakan, and Qiang Qu say that digital twins let you simulate different scenarios and configurations without disrupting the actual production process.
This is a great way to test and optimise production processes, which helps to improve quality control and predictive maintenance.
The CSIRO’s Data61 Mixed Reality Lab is a great example of how digital twins are being used in design and development.
The lab uses some pretty advanced optical cameras and sensors to get a good look at objects.
This lets them create digital twins that can be compared against original designs to spot any problems early in the production process.
As a starting point for understanding digital twins in the context of AEC projects, you might find it helpful to read “Forget One-Size-Fits-All: Right Type of Digital Twins for Your AEC Needs.”
Production and Operations
In production and operations, digital twins help us to monitor and optimise things in real time.
By putting IoT sensors and machine learning algorithms to work, manufacturers can gather and crunch data from their physical assets to boost efficiency and predict maintenance needs.
Ebnia et al. say digital twins in smart manufacturing help test and optimize production processes, which improves quality control and cuts costs.
CSIRO’s research backs up these findings. For instance, their work in metal additive manufacturing uses digital twins to make sure the output is high-quality and the processing windows are just right, which means they can cut costs and make products that are more reliable.
Maintenance and Asset Management
Digital twins help us to predict when equipment might fail, so we can plan ahead and avoid any nasty surprises.
Ebnia et al. suggest that predictive maintenance is a key part of digital twins in smart manufacturing. This helps to keep output high quality and cut operational costs.
CSIRO’s use of digital twins in metal additive manufacturing is a great example of this in action.
By keeping an eye on everything, digital twins can spot problems before they become big problems, so production keeps on running smoothly.
Supply Chain and Logistics
Digital twins, like the one used for Cross River Rail, show how this technology makes complex logistics and planning processes easier in large-scale infrastructure projects.
It also helps you understand how the physical infrastructure is performing.
Simply put, digital twins give you a complete view of the whole network, from getting the raw materials to delivering the product.
This visibility helps us to spot bottlenecks, improve inventory management and make sure everyone’s on the same page.
Ebnia et al. also mention how digital twins can help make supply chains more efficient by providing real-time data and predictive analytics, which are essential for maintaining responsive supply chains.
Features of Digital Twins in Manufacturing
One of the main cool features is real-time data integration. This means combining data from different sources, like IoT sensors, ERP systems, and CAD models.
The integration gives managers and engineers a complete picture of the manufacturing process, so they can make decisions based on real-time data.
Another key feature is simulation and modelling. This lets manufacturers try out different scenarios in a virtual environment.
By simulating different scenarios, manufacturers can predict what’ll happen and make their processes more efficient without disrupting what they’re already doing.
Predictive analytics is a really useful feature of digital twins. Advanced algorithms in digital twins can even predict potential issues before they become significant problems.
Another key feature is interoperability, which makes sure that digital twins can easily link up with existing manufacturing systems and software.
As Ebnia et al. point out, these features are key for creating smart manufacturing systems that can adapt to changing demands and make production processes more efficient.
You can see these features in action at CSIRO.
Their work shows how digital twins can really boost production efficiency and quality control.
The Mixed Reality Lab at CSIRO’s Data61 shows how real-time data integration, simulation, predictive analytics, and interoperability can work in the real world in a manufacturing environment.
Adopting these features will help manufacturers become more efficient, improve quality control, and make their operations more resilient.
You might find it helpful to read “More Profit, Less Hassle: The Azure Digital Twins Guide for Busy Leaders.”
Challenges and Solutions
There’s no doubt that digital twins have a lot to offer, but there are a few hurdles to overcome before they can be fully implemented.
One of the main challenges is managing all the data. Yup, the amount of data produced by digital twins can be pretty overwhelming,
That’s why having robust good data management and analytics systems in place is a big deal in every digital twins applications.
Ebnia et al. say that using advanced data analytics and big data tech is key for managing and making sense of all the data produced by digital twins.
Another big challenge is integrating with existing systems. CSIRO’s research shows how important these steps are for making sure everything goes smoothly and that digital twins can deliver the best results.
It can be tricky to make sure digital twins work well with the current manufacturing infrastructure.
Using standardised protocols and interoperable software can help to avoid these issues when it comes to integrating digital twins.
It’s important to plan carefully and use compatible technologies to make sure digital twins can be integrated into existing systems effectively.
Another thing to think about is cost when you’re implementing digital twin technology.
The upfront cost can be high, covering the costs of new software, hardware, and training for personnel.
But the long-term savings in maintenance and operational efficiency often make the expense worthwhile.
Both Ebnia et al. and CSIRO’s research show that digital twins are worth the investment. The advantages of digital twins in terms of reduced downtime, improved efficiency, and enhanced quality control outweigh the initial setup costs.
Customised Digital Twin Solutions for Manufacturing
The complexity and uniqueness of digital twins, along with the specific needs of each manufacturing project, mean that a tailored approach is needed.
You can’t just buy off-the-shelf solutions and expect to get the best results.
That’s why we’ve got bespoke digital twin services that we can tailor to your specific goals and requirements.
Our team of experts work closely with you to create accurate and impactful digital twins that mirror your manufacturing processes.
Together, we make sure that every part of your operations is accurately represented in the digital world.
We don’t just set up your digital twins and leave it at that. We keep them up to date and make sure they stay relevant as your operations change and grow.
What’s more, we can easily add digital twins to your current workflows, so there’s no need for any disruption.
This integration lets you get the most out of digital twin technology without having to overhaul your current systems.
You may want to do a few background checks on us before you get started. We also don’t want you to get hooked on all the marketing hype and end up with diabetes.
So, as a taster, please take a look at our BIM Management Support page.
And please feel free to book a lunch meeting with us. We’re here for you 24/7 if you need to discuss your specific needs.
In Closing
The rise of digital twins has changed the way businesses operate. It gives them real-time insights that help them work more efficiently and save money.
If manufacturers use digital twin technology, they can get more done, and do it better.
By embracing these new technologies, manufacturers can fully leverage the benefits of digital twins in manufacturing processes.
