October 11, 2022
Smart manufacturing relies on supply chain, factory, system, and equipment data. To monitor and analyze constantly changing information in their production process, manufacturers exploring industry 4.0 applications use the real-time data power of digital twins.
In smart manufacturing, the advantages and benefits of using digital twins are plentiful. From anticipating maintenance issues to evaluating product upgrades and informing financial decisions, digital twins give companies the predictive insights to achieve their business goals. Here are five examples of how digital twins address the different needs of smart manufacturing.
By creating a virtual replica connected to the physical asset, digital twins give smart manufacturers the real-time insights they need to make production decisions quickly. Because the delays associated with physical products are removed — hardware, labor, materials, etc. — operators can speed up every step of the manufacturing process, including design, development, testing, and maintenance.
Case study: ENGIE Lab CRIGEN relies on Ansys' digital twin technology to accelerate the zero-carbon energy transition for its customers.
Using a digital twin enables smart manufacturers to predict the quality of the end product, helping them make more informed decisions about issues such as material upgrades and process enhancements. In industrial manufacturing, digital twins help ensure consistency across large-scale production so the end product is always in line with specifications.
Case study: Kärcher uses Ansys digital twin technology to simulate different battery cells and housing materials in real-world situations.
Digital twins empower operators to continuously monitor processes and systems to evaluate the most efficient methods. If the production flow isn’t operating at the ideal capacity, a digital twin will immediately reveal opportunities for improvement. By increasing production efficiency, digital twins help smart manufacturers reach their sustainability goals by reducing energy and material consumption.
Case Study: The EDF Group (EDF) uses Twin Builder to design nuclear power plants.
In smart manufacturing, unplanned downtime can cost tens of thousands of dollars per hour. Digital twins give operators the foresight to anticipate issues based on different environmental pressures and scenarios. By using digital twins to look into the internal workings of their complex devices, manufacturers can predict when issues will occur and attend to maintenance concerns before they disrupt the entire production.
Virtual commissioning enables early validation of system designs to predict and solve problems that happen when machines and processes are integrated for the first time. In smart manufacturing, digital twin technology shows how entire systems will interact — not just individual devices, but how each device will influence the performance of an entire production floor.
Case study: Rockwell Automation uses Twin Builder to provide insights and improve system performance.
See what a digital twin could do for your company. Get started with a free trial of Ansys Twin Builder.
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