With every year that goes by, the use of Digital Twins is being adopted more and more by different industries. From machine shops and metal fabricators to food manufacturers, energy, forestry, and chemical industries, the range of applications and requirements for a Digital Twin is almost as wide as the number of industries and manufacturing companies.

Process Genius has extensive experience in industrial environments, and in our many years of service, we have seen that the needs of industrial operators typically center around things like controlling production costs, allocating resources as efficiently as possible, and managing day-to-day operations.

Are you curious about how your production and daily management operations could be built upon the Digital Twin? In this article, we’ll give you a sneak peek at how industry leaders are leveraging this technology to optimize their operations, enhance productivity, improve operations management, and so much more.

Examples and use cases how Digital Twins are used in manufacturing and process industries

Predictive maintenance

Digital Twins play a crucial role in predictive maintenance, enabling manufacturers to detect potential equipment failures before they occur, reducing downtime and improving operational efficiency. Konecranes, a global leader in material handling solutions is using Smart Factory Digital Twin in its manufacturing facility to predict and prevent outages, optimizing maintenance schedules and ensuring continuous production. In addition, Konecranes offers Smart Factory to its customers as a daily management tool that provides them with a complete view on what is happening in the factory. Read full customer story.

Production optimization

Digital Twins are utilized to optimize manufacturing processes by observing different scenarios and identifying the most efficient ones. CNC-Machining Ltd, a company specializing in light and mid-heavy CNC machining, utilizes Digital Twin to monitor maintenance and to maximize productive time and use of existing resources, enabling adjustments to be made in production to reduce waste. Read full customer story.

Quality control

Digital Twins are employed to monitor production quality, ensuring that products meet specified standards. Snellman, one of the leading food industry companies in Finland, employs Digital Twin to monitor cooking processes in real-time, enabling immediate adjustments to be made during production to maintain product quality and reduce waste. Read full customer story.

Data-driven decision making

Digital Twins are applied to improve data-driven decision-making by providing real-time visibility on processes and giving insights on future scenarios. Stora Enso uses Digital Twins in its mill sites both in Finland and abroad to consolidate data, and to get a clear understanding of the situations in a factory at any given time, enabling better decision-making and forecasting. Read full customer story.

digital twin examples

Onboarding and documentation

Digital Twins are used to create virtual training environments, allowing employees to practice operating equipment and processes in a safe and controlled setting. A company specializing in mineral processing employs Digital Twin to train new workforce and assist contracted maintenance workers, reducing the risk of accidents and improving overall operational skills. Read full use case.

Energy efficiency

Digital Twins are utilized to optimize energy consumption and reduce carbon emissions in manufacturing processes. A company specializing in the manufacturing of plastic parts uses Digital Twin to monitor and analyze energy usage in its manufacturing plants, identifying opportunities for energy savings and reducing environmental impact. Read full use case.

The future of manufacturing lies in the power of Digital Twins

Through the real-world examples and use cases presented in this article, Digital Twins have already made a positive impact in various sectors of manufacturing. As an example, industrial machinery and equipment experts are utilizing Digital Twins to monitor equipment lifecycle, enabling proactive maintenance, and decreasing unplanned downtime. Food and other processing pioneers are using this technology to simulate and optimize production processes, resulting in higher productivity and resource efficiency.

The future of manufacturing lies in the power of Digital Twins. With advancements in artificial intelligence and connectivity, these virtual replicas will become even more sophisticated and capable of driving innovation. As many manufacturers embrace digital twins, they will gain a competitive edge in today’s rapidly evolving industry.

So, whether you are a process manager looking to optimize your production line or a company leader aiming to stay ahead of the curve, Digital Twins are a technology worth exploring. If you want to learn more about our Digital Twin solutions for the manufacturing and process industries, please drop us a line and we will get back to you!

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