Introduction to digital twins in manufacturing
Digital twins in manufacturing represent entire lines of production, individual assets, and various products in the production process. Generally, a digital twin represents a virtual model that processes a physical asset and a system to enable decision-making for business operations—the digital twin merges physical reality with digital data, enhancing operational efficiency in the product life cycle. The system presents the digital representation with continuous effort and real-time conditions. Specifically, the system contains detailed information regarding products and assets. Moreover, accessed across various organizations in deeper manufacturing processes. Digital twins analyzes production processes with predictive maintenance and monitors the products.
Benefits of digital twin technology in manufacturing
Prototyping and design enhancement
Digital twin technology helps manufacturers create models virtually with the help of various tools. In this case, with the help of digital representation, engineers design their virtual environment. In the initial stages, the technology helps to identify the issues and ultimately reduce them during production (Onaji, Tiwari, Soulatiantork, Song, & Tiwari, 2022). The technology helps in speeding up the design cycle and managing modifications during manufacturing.
Continuous performance monitoring
In machine tool manufacturing, continuous performance monitoring helps to reduce repairs and avoid downtime. The system manages both real-time monitoring and operational performance. The predictive maintenance user schedules and prevents unplanned breakdowns. Moreover, ensures that machines run smoothly to reduce the repair and increase the performance.
Optimized production efficiency
With the help of various interactions and manufacturing systems, digital twin technology optimizes the process. The technology helps in the usage of machines and identifies inefficiencies. Moreover, assists in operating the high production with low operational cost. Also, the system contributes to a quick production cycle for enhanced resource management.
Cost reduction
Digital twins help to reduce cost with the facilitation of virtual prototyping. In addition, the technology identifies the bottlenecks in the initial stage to avoid costly mistakes. Furthermore, the system uses various production scenarios to shorten the time.
Support environmental sustainability
In fact, digital twin technology helps to optimize the manufacturing process. The technology enhances product designs and minimizes wastage (Attaran, Attaran, & Celik, 2023). Moreover, the system enables to make decisions effectively and reduces overall environmental footprint on manufacturing process. In addition, helps in improving the product traceability and ensures a sustainable approach.
Benefits of digital twins in manufacturing
Applications of digital twins in smart manufacturing
Continuous improvement of manufacturing system with digital twin
In fact, digital twin technology enhances the efficiency and cost-effectiveness of manufacturing systems. With the simulation of real time, businesses continuously improve operations with the involvement of digital twins. Hence, the technology allows for better equipment and a longer lifespan. For example, Hitachi is using digital twins to make use of instability, such as identifying the potential issues before they arise and operating the efficiency.
Part production monitoring and modification using digital twin
Basically, digital twin technology enhances the quality in various stages. With the virtual representation of machines, the system monitors the entire production process in real time (Crawford, 2021). The key parameters such as temperature, flow rate, and pressure are involved. For example, the data reveal that the machine produces a high number of defective parts, which progresses towards improving the quality and production output.
Reducing downtime in part production with digital twin
The major application of digital twin technology is minimizing downtime. With the minimization, the system helps in major settings to identify potential problems. For instance, the adjustments for machine speed and temperatures are tested before any potential issues. With the monitoring of the production process, digital twin addresses the issues in the very early stage, significantly reduces unplanned downtime.
Enhancing safety with the identification of risks and hazards in manufacturing
The digital twin technology played a very crucial role in manufacturing safety. By providing better insights into risks enables preventive actions. The digital twins monitor the operating conditions and health of machines before there is any danger. The technology identifies different hazards and provides an understanding of the risks involved. A proactive approach allows a safer manufacturing environment and eliminates the potential occurrence of accidents.
Challenges of digital twins in manufacturing
Newness of the technology
Digital technology could raise concerns regarding application and usage in manufacturing. There is a lack of technical knowledge to understand productivity and efficiency (Singh & Gameti, 2024). Consequently, the system delay could also affect the companies.
Time and cost constraints
In the manufacturing industry, the major focus is on both guarding cost reduction and investment. Making a digital representation of a manufacturing system specifically needs substantial time. The need for high-performance computing indicates expenses and financial capacity to invest in advanced technologies like digital twins.
Lack of standardization
In the manufacturing sector, the system majorly depends upon regulations and standardized procedures, which face complexity in digital twin technology. Consequently, the system leads to compatibility issues. Moreover, slows down the implementation process and raises concerns regarding security and accessibility.
Challenges of digital twins
Conclusion
The integration of digital twin technology in the smart manufacturing process optimizes the production process and product quality. The creation of physical items enables real-time manufacturing and enhances decision-making. The digital representation prefers to manufacture, operate, and predict potential issues to increase performance. However, the technology has major benefits regarding adoption with digital twin technology. There are also challenges associated with high cost and absence of data privacy issues. Moreover, the expansion of digital twins into the latest sectors improves interoperability between various technologies. To conclude, digital twins improve efficiency with precise monitoring and managing of complex systems.
References
Attaran, M., Attaran, S., & Celik, G. (2023). The impact of digital twins on the evolution of intelligent manufacturing and Industry 4.0. Advances in Computational Intelligence, 3(11), 1-14. Retrieved from https://www.researchgate.net/publication/371370689_The_impact_of_digital_twins_on_the_evolution_of_intelligent_manufacturing_and_Industry_40/link/6480c8ea79a722376516fff7/download?_tp=eyJjb250ZXh0Ijp7ImZpcnN0UGFnZSI6InB1YmxpY2F0aW9uIiwicGFnZSI6InB1YmxpY2F
Crawford, M. (2021, Mar 17). 7 Digital Twin Applications for Manufacturing. Retrieved from Asme: https://www.asme.org/topics-resources/content/7-digital-twin-applications-for-manufacturing
Onaji, I., Tiwari, D., Soulatiantork, P., Song, B., & Tiwari, A. (2022). Digital twin in manufacturing: conceptual framework and case studies. International Journal of Computer Integrated Manufacturing, 35(08), 831-858. Retrieved from https://eprints.whiterose.ac.uk/id/eprint/183303/1/0951192X.2022.pdf
Singh, A. P., & Gameti, N. (2024). Digital Twins in Manufacturing: A Survey of Current Practices and Future Trends. International Journal of Science and Research Archive, 13(01), 1240–1250. Retrieved from https://ijsra.net/sites/default/files/IJSRA-2024-1705.pdf
Keywords
Manufacturing systems, Smart manufacturing, Digital Twin technology, Digital representation, Predictive maintenance,
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