In manufacturing, the key to thriving is a constant evaluation of process improvement. And the creation of the digital twin enables manufacturers to achieve exactly that. With the right tools and capabilities, digitalization increases efficiency in all phases of production.

Digitalization is primarily driven by four disrupting factors:

  • The drastic rise in process data and exponential growth in computational power/connectivity
  • The vast improvement in digital data transfer from the virtual space to the physical world
  • Emergence of predictive analytics and other business-intelligence capabilities
  • New forms of human-to-machine interactions

The benefit to both design and production is an acceleration of new product introduction. But in order to maximize the benefits of the digital twin, companies must create an effective feedback loop between production and design.

Gaining Visibility into the Digital Enterprise

The old age of manufacturing as a static, segmented process where detailed information was gathered on any factory operating equipment through manual methods. Equipment was visually inspected and recorded data was read directly off the machine.

Today, increased computing power makes it possible to gather the same information remotely through virtual means by creating a digital representation, or “digital twin,” of the same equipment where the computer model is generated using recorded sensory input and computer-aided modeling. Ultimately, the goal of the digital twin is to create, test, build, and monitor equipment and process in a virtual environment. In doing so, asset visibility is either created or improved through its model (53%) and data can be gathered for use in predicting potential downtime (36%).


With the right tools and capabilities, digitalization allows design validation and machine configuration management checks to be made earlier and more often. This small adjustment helps reduce the risk of errors or catastrophic failures during critical manufacturing phases, saving the organization money and man hours. If machine status is available on an integrated data platform, tests and modifications, even those that are the same but globally dispersed, can be executed in the same manner. Thus, eliminating the potential for error due to inconsistencies.

Learn more about how digitalization in manufacturing can open the door to new revenue streams and value-producing opportunities for your organization by checking out, Choosing All Three: Fast, Good, and Cheap Using the Digital Twin.

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