Keeping digital twins usable in the long term through process mining and simulation

With the official launch of Minulate in December, a new ZIM research project has been launched that addresses a central problem of digital twins: their long-term relevance and reliability in operational use.

Together with the West Saxon University of Applied Sciences Zwickau and the Industry Analytics research group, SimPlan AG is working on an approach that makes digital twins more robust against changes in real production and logistics processes.

Objectives of the research project

The aim of Minulate is to develop an IT service for the automated synchronisation and self-healing of digital twins. To this end, three methods are systematically combined:

• Process mining for data-based analysis of real processes
• Material flow simulation for the evaluation of future scenarios
• Data analytics for continuous deviation analysis

This should enable digital twins to adapt dynamically to changing processes and serve as a valid basis for decision-making in the long term.

Role of SimPlan AG

SimPlan AG is responsible for the design and development of the IT service. The focus is on a modular and scalable software solution that can be used both as a stand-alone service and as an extension of existing digital twins.

A key aspect is the automated adaptation of simulation models based on real process data with the aim of reducing maintenance costs and significantly increasing the service life of digital twins.

Outlook

Minulate addresses a clear need in industry and logistics. Digital twins must keep pace with reality in order to remain economically viable. The project lays the foundation for new software solutions at the interface between simulation and process mining.

The project is scheduled to run from November 2025 to October 2027. Initial prototypes and practical tests are planned during the course of the project.

Project partners

• SimPlan AG
• West Saxon University of Applied Sciences Zwickau
• Industry Analytics Research Group

The research project is funded by the Federal Ministry for Economic Affairs and Energy (BMWE).
Funding began in December 2025 and is expected to continue until March 2027.