Digital Manufacturing • DM-02
Digital Twin
A live model of the plant that answers questions before you commit to the change.
Scope
What the engagement covers.
Twins are only useful when they are calibrated against real behaviour and used for real decisions. This service builds process and asset twins tied to live data with defined decision use cases.
Included capabilities
- Asset and process twin modelling calibrated on production data
- Simulation of throughput, quality and energy under changed conditions
- What-if analysis for line changes, product mix and maintenance windows
- Visualization tied to plant layout and equipment hierarchy
- Model validation and drift management as the plant changes
Outputs and deliverables
- Calibrated twin with documented accuracy bounds
- Simulation scenarios and what-if analysis toolset
- Validation report against withheld production data
- Recalibration procedure and drift thresholds
Workflow
How it is delivered, step by step.
Each step has an owner, an entry condition and an artefact that has to exist before the next step begins.
01DefineDecisions the twin must support, and the accuracy those decisions need.
02ModelPhysical and process modelling with parameter identification.
03CalibrateFit against historical production and known event data.
04ValidateBlind test against withheld periods before operational use.
05MaintainDrift monitoring and recalibration as equipment and product change.
Use cases
Where this is typically applied.
Optimizing changeover sequence across a variable product mix
Training operators on abnormal conditions safely
Delivery model
The operating pattern for Digital Manufacturing.
The same delivery discipline applies across every capability in this line, so combined engagements stay coherent.
Baseline
Asset register, data availability, loss analysis and value case per line.
Connect
Sensors, gateways, historians, protocol translation and network coverage.
Model
Twins, failure models, OEE logic and analytics validated against real events.
Deploy
Operator and maintainer workflows, alerts, dashboards and situation centre.
Scale
Second line, second site, standard templates and capability transfer.
Integration
- MES, APS, ERP and CMMS so insight becomes a work order, not a dashboard.
- SCADA, historians and PLC layers via standard industrial protocols.
- Quality and laboratory systems for genealogy and root-cause analysis.
- Private LTE/5G or industrial Wi-Fi for coverage in electrically noisy plants.
Engagement approach
Deployment starts on one line or one asset class where losses are measurable, so the business case is proven on real production data before the site-wide rollout is committed.
Related
Other capabilities in Digital Manufacturing.
DM-01
AI Technical Monitoring
Catch equipment failure while it is still cheap to fix.
DM-03OEE / Asset Scoring
One honest number for equipment performance, built from data nobody can argue with.
DM-04Situation Center
One room where production, maintenance, quality and energy are looked at together.
DM-05AI Maintenance Assistant
Put twenty years of maintenance knowledge in the technician’s hand.
DM-06Robot Fleet Management
Treat robots and AGVs as a managed fleet, not as isolated machines.
DM-07MES / APS / SCADA-HMI Integration
Make the execution layer, the planner and the control layer agree.
DM-08Private LTE/5G & Industrial Connectivity
Coverage that survives metal, movement and electrical noise.
DM-09Smart Workshop
Digitize the workplaces where most variability actually originates.
DM-10Industrial Safety
Detect the unsafe condition before it becomes the incident report.
DM-11Environmental & Energy Management
Attribute energy and emissions to the process that actually consumed them.