Smart manufacturing digital twins

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• Author name

  Quantumrun Foresight
• December 15, 2023

Insight summary

Digital twins in Industry 4.0 offer a transformative approach to manufacturing, where physical processes and products are replicated digitally in real-time using technologies like 3D, VR/AR, and real-time data analysis. This innovation allows companies to simulate scenarios, optimize operations, and predict maintenance needs, enhancing efficiency and reducing costs. While it revolutionizes industries like automotive manufacturing, it also raises concerns about cybersecurity and labor shifts, necessitating skilled technical workers. The adoption of digital twins signifies a move towards more competitive, innovative, and environmentally conscious manufacturing practices.

Smart manufacturing digital twins context

A digital twin uses 3D technology, and virtual and augmented reality (VR/AR) to transpose the physical attributes of a factory, product, or process to the digital realm in near real-time. By connecting objects that generate real-time data, it is possible to create a digital profile of a product from design to production. Data can be processed and aggregated based on different criteria and presented in various forms depending on specific use cases. This practice results in an evolving digital profile that incorporates historical and current behavior, leading to richer models and more realistic measurements of a system's inherent weaknesses over time.

When discussing a digital twin, the traditional focus is on design. While many manufacturers claim to have a digital twin of their machine based on 3D models or representations, a digital twin encompasses more than just designing parts. Machines are no longer solely mechanical components; adaptability drives them in various ways. With the advent of more advanced 3D software, machines are becoming increasingly flexible and adaptable.

Implementing smart manufacturing is crucial in creating mechanical, electrical, or software parts and driving them down into specific manufacturing disciplines. Some digital twin providers facilitate the automation of the production process by generating Computer Numerical Control (CNC, used to control machinery's movements), Computer-Aided Manufacturing (CAM) programs, and Coordinate Measuring Machine (CMM, a device that measures the physical attributes of an object). 

Disruptive impact

A digital twin is valuable throughout the production process, not just at the beginning. By constructing a well-designed digital twin, companies can simulate potential scenarios and predict outcomes, allowing them to test new digital strategies before deploying them in the real world. This approach not only saves time but also helps to identify potential flaws in a design before it is implemented, mitigating possible disruptions. 

Additionally, by analyzing the performance of machines and the quality of products at each manufacturing stage, they can be optimized to produce better outputs at a lower cost. Moreover, predictive maintenance through near-real-time tracking of components can alert staff to potential breakdowns, enabling them to avert issues before they occur. This process ensures that production runs smoothly and minimizes costly downtime.

In the automotive industry, for example, digital twins can be applied to various car models, generations, and configurations to design the type of microcontrollers, sensors, actuators, and installed software components. Production activities can be tracked through RFID (Radio-Frequency Identification) antennas that log information on each new component box. Digital twins can help harmonize various data models and automate the data collection process, enabling researchers to access detailed information, such as vehicle speed, without needing to know the technical details of the specific platform.

Implications of smart manufacturing digital twins

Wider implications of smart manufacturing rise may include: 

• Companies being able to compete more effectively in the global marketplace, potentially leading to increased economic growth and job creation.


• Changes in labor requirements, as the need for manual labor decreases and the demand for skilled technical workers increases. Additionally, the adoption of smart manufacturing digital twins may require a skilled workforce capable of managing and maintaining the technology.


• Optimized use of resources, such as energy and raw materials, leading to reduced environmental impact and lower costs.


• As manufacturers become more reliant on digital twins and connected devices, they may become more vulnerable to cybersecurity threats, leading to potential economic and political implications.


• Concerns around data privacy and security as these systems collect massive amounts of information, including employee movements.


• Increased innovation in manufacturing processes and solutions, such as the Internet of Things, private 5G networks, and advanced cobots.


• More business opportunities for companies that provide digital twin solutions and customized services.

Questions to consider

• If you work in manufacturing, how is your company investing in Industry 4.0 tech like digital twins?


• What are the potential challenges of implementing digital twins in factories?