Manufacturing with Real-Time View: How Digital Twin Improves Visibility

Conventional manufacturing processes only highlight risks, problems and issues during or after a product has been made, causing time-consuming and costly ramifications.

To implement modern manufacturing practices in a connected industry with sustainability weaved into every step, manufacturers can leverage the virtual twin. It enables them to rely less on manual input and more on data-driven analysis.

Using the virtual twin, manufacturers can develop an accurate digital version of a product and the elements needed to create these products. Accelerating manufacturing processes’ effectiveness and viability, this key technology plays an important role in optimization because it allows manufacturers to validate risks, analyze options and obtain a deeper understanding of their processes before committing to actual operations.

The virtual twin turns the value chain into a connected virtual experience. By creating visibility of the entire product lifecycle, it can help manufacturers:

• Deliver more sustainable manufacturing practices
• Identify and address issues earlier at the design stage
• Reduce waste and improve energy use

"The virtual twin presents a significant opportunity to drive efficiencies across organizations,” said Lauren Ing, Accenture’s Senior Manager of Sustainability Strategy. “Whether that’s reducing costs through materials savings, understanding how you can efficiently design, package or produce a product, improving quality control, and identifying the most efficient and safest way to launch or speed up the time to market.

In times of economic uncertainty, the virtual twin equips manufacturers with better decision-making ability, enabling them to deliver the most cost-efficient and resilient outcomes when it matters the most.

Manufacturers on a mission to instill circular principles in their processes are turning to innovative, cutting-edge solutions. Ideally, these solutions help manufacturers remain competitive while keeping them on track to meet their sustainability goals.

Research conducted by the United Nations in collaboration with Accenture found that a total of 99 percent of CEOs from companies with more than €1 billion in annual revenue believe that sustainability is a decisive factor in the success of their business.
 
This is where advanced technology like the virtual twin can advance manufacturers sustainability goals and fast-track innovative results. Dassault Système’s integrated 3DEXPERIENCE® platform enables customers to collaboratively experience the virtual twin to keep their entire operations running lean and smooth for greener manufacturing.

From simulating factory floors to monitoring human and machine interactions, the virtual twin supports manufacturers to:

No manufacturer wants to deploy equipment on its factory floor only to discover design errors after built-out systems are installed. CenterLine (Windsor) Limited, a Canadian industrial automation process and technology company, sought to eliminate the time and money spent fixing these design errors.

On the 3DEXPERIENCE platform, CenterLine used DELMIA Robotics to virtually simulate its products, processes and factory operations to sync with its robot movements, optimizing the use of shop floor space, material flow and ergonomic safety. This enabled the company to cut programming time on the factory floor and lower their tooling-related issues by up to 75 percent and 90 percent respectively.

Using the 3DEXPERIENCE platform, manufacturers can introduce sustainable innovations at the heart of their business operations. In doing so, they can elevate their strategy, design and production towards leaner and more circular processes.

Safety and security can also be enhanced using the 3DEXPERIENCE platform. Manufacturers can simulate hazardous locations such as nuclear power plants or mines and workers can practice within accurate, realistic representations of the existing environment.

Evolving from a physical to a virtual factory gives manufacturers real-time views of their products' anticipated use and outcomes. They can imagine endless possibilities by simulating various conditions and gain data-driven results. With each result, surprises become rarities- manufacturers can make informed business decisions, take action to reduce errors, maximize resources and minimize waste.