Best Digital Twin Software

In the manufacturing sector, operations often rely on elaborate machine systems. This equipment can perform any number of complex tasks, but also requires constant maintenance, monitoring, and improvements to ensure consistent output. Traditionally, inspections have been done manually, with sizable room for error and oversight. Now, thanks to internet of things (IoT) technology, engineers and factory managers can streamline these processes and continuously optimize machines without the need for rigorous physical inspections. Digital twin software is an advanced form of simulation software, using sensor data from embedded machines to create accurate, real-time simulations of assets. These virtual models allow for intelligent structural assessments and analyses, with actionable insights into machine performance and maintenance needs.

Using digital twin technology, manufacturing teams can design true-to-life virtual representations of their most vital assets and, in some cases, complete systems or factory floors. These products may also have use cases outside of manufacturing, such as in health care and utilities. With these interactive visual twin models, users can compare their initial designs with the actual performance of distributed assets. Some products help to create alerts when anomalies are detected by embedded sensors (e.g., unexpected downtime, overheating) or when components are approaching their scheduled maintenance. Users can conveniently pinpoint the problem areas in large, complicated machines on virtual models, and administer predictive maintenance on the actual assets without the guesswork. Throughout the asset lifecycle, teams can utilize digital twin technology for maximum process optimization, while minimizing costs, waste, and disturbances. The digital twin concept is rapidly transforming factory operations across the globe, and the products in the category empower business teams to realize the benefits in their own operations.

Key Benefits of Digital Twin Software

• Detect equipment issues remotely and proactively
• Minimize downtime and costly process failures
• Increase production yield and overall supply chain outcomes
• Make informed decisions toward design and engineering of machines

Digital twin platforms help modernize global manufacturing operations, with unprecedented insights into industrial equipment processes and their many physical components. The digital models made possible with these solutions can help factory workers and supervisors visualize the inner workings of machines and machine parts, with real-time data about asset health, performance, and conditions. In some cases, digital twin technology allows users to simulate events in the manufacturing process (e.g., new connections between machines, updated machine processes and data flows), so they can determine the best course of action before implementing actual changes. Products may offer visual analytics related to these simulations, turning machines and their smallest components into powerful data sources and helping users understand their equipment in ways not previously possible.

Predictive analytics—such as those made possible by predictive analytics software—are a key benefit of digital twin technology. Sudden machine failures can result in substantial losses, as well as delays in production and employee frustrations. The various analytics made possible through these solutions allow users to anticipate the litany of issues that might arise with machine systems and devices, while monitoring overall performance metrics to shape continuous improvements toward processes and designs. Data generated on these products might also assist with predictive waste reduction and predictive quality control of completed products, as well as general optimization of resources. Additionally, if any machine or process issues are identified, users can investigate their root causes by exploring virtual models and the data gathered across embedded sensors. This can help manufacturing teams make lasting improvements wherever possible, rather than simply patching up the symptoms and side effects of serious foundational problems. All in all, digital twin technology can give engineers and factory managers a newfound level of control over their distributed assets, helping to protect these critical investments and ensure consistent, optimal production without the unexpected surprises.

Digital twin technology is primarily used in the manufacturing industry, or those businesses that utilize robust production equipment to convert raw materials into finished products or parts. With that being said, this technology is finding new use cases in a number of other industries with complex distributed assets, where virtual simulations may come in handy for prototyping or predictive asset data. As this technology becomes more prevalent, it may be integrated into the business models for additional industries while further cementing its place in manufacturing operations both big and small.

The following are some specific roles or teams that may benefit most directly from digital twin technology in their daily job functions.

Mechatronics engineers — The rise of smart technology has created a strong demand for industry specialists that can apply these modern principles to the design and deployment of industrial systems. Mechatronics engineering is a fast-growing specialization for developing the types of intelligent manufacturing systems that are compatible with digital twin technology. There are a variety of specific job titles that may be included in the field of mechatronics engineers or that may be tasked with similar responsibilities, such as senior design engineer, equipment engineer, and automation specialist.

Machinists — Machinists are often assigned to set up, operate, and maintain computer and mechanically operated machines that produce parts used in manufacturing. As industry equipment and devices evolve, so do the expertise and job functions of machinists and machine operators. Digital twin technology is increasingly used by these specialists to help prototype machine designs and processes, as well as maintain these systems, across a wide spectrum of industries. Job titles that may fall under the umbrella of machinists include mechanical technician, industrial engineering technician, and plant operator. These roles are also commonplace in highly technical industries such as aerospace. Machinists in these advanced roles or standard manufacturing operations may leverage digital twin technology to gain high-level visibility into their machines and proactively maintain them using data from embedded sensors.

Production managers — Production managers and supervisors oversee the daily operations of manufacturing plants, from managing workers to ensuring speedy repairs related to production problems. Digital twin technology can provide these individuals with timely operational data related to critical assets, so they can make informed decisions about equipment maintenance and process flows. The products in this category may become invaluable tools for production managers of operations utilizing smart technology or those planning to integrate this technology across physical assets. Some specific job titles that fall under the umbrella of production managers might include manufacturing process engineer and assembly supervisor. For many factory operations, supervisory teams hold a great deal of responsibility with regard to machine upkeep and optimization. Digital twin platforms can empower these individuals with the most timely and specific insights into smart machinery so they can ensure the operation runs smoothly and produces at the highest possible level.