The Digital Twin as a Tool for Better Decision-Making
Digital twins are regarded as a key component of the digital factory. Nevertheless, many projects fall short of expectations. Often, large volumes of data are collected and visualised without this resulting in any concrete added value for planning, optimisation or decision-making. It is not the technology alone that is crucial, but rather how a digital twin is utilised. Simulation, emulation and virtual commissioning play a central role in this.
Data alone does not constitute a digital twin
Many projects focus on the collection and presentation of data. Sensors provide information from production, dashboards visualise key performance indicators and data platforms store large volumes of operational data. This information is important, but it merely forms the foundation. It shows what is happening now or what has happened in the past.
A true Digital Twin goes one step further. It helps to understand interrelationships, identify risks and prepare for decisions. Only then does a measurable benefit for the company arise.
Without simulation, there is no insight into the future
Data describes reality. Simulation makes it possible to examine potential future developments.
For example, companies can analyse:
- new production concepts
- material flows
- capacity limits
- potential bottlenecks
The major advantage is that decisions can be assessed virtually before changes are implemented in the real plant. This reduces risks and creates a robust basis for investments and optimisation measures.
Emulation tests the control system before commissioning
Another key component of modern digital twins is emulation. Here, the real control software communicates directly with a virtual plant model. This allows functions and processes to be tested without the need for the real plant to be available.
Typical use cases include:
- Testing of PLC programmes
- Review of material flow strategies
- Validation of plant logic
- Analysis of faults and exceptional events
Errors are thus detected much earlier and can be rectified even before commissioning.
Virtual commissioning reduces risks
Virtual commissioning is based on simulation and emulation. Control systems and processes are tested in a virtual environment before the real plant goes into operation.
This makes it possible to:
- Detect errors at an early stage
- Shorten start-up times
- Avoid production downtime
Particularly in the case of complex production and logistics systems, virtual commissioning can help to reduce project durations and ensure the smooth ramp-up of new plants.
The benefits must be clearly defined
Many digital twin projects begin with a decision on the technology to be used.
Successful projects, on the other hand, start with a specific question:
- Where do bottlenecks occur?
- How can the plant ramp-up be ensured?
- Which variant is more cost-effective?
- How can downtime be reduced?
The use case determines the digital twin, not the other way round. Only when the benefits are clearly defined can a tool be created that actually contributes to improving processes.
The future brings together multiple worlds
The next generation of digital twins combines various technologies into a holistic system.
These include, amongst others:
- Real-time data from production
- Simulation models
- Emulation environments
- Virtual commissioning
- AI-supported analyses
This combination creates a digital replica that not only provides information but also actively supports decision-making.
From digital replica to decision-making system
The Digital Twin is increasingly evolving from a pure monitoring tool into a decision-making system.
Modern Digital Twins help companies to
- assess future developments
- to validate control systems
- to prepare for commissioning
- to continuously improve processes
The real added value does not come from the volume of data collected, but from the ability to derive well-founded decisions from this data.
