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Manufacturing Digital Twin Powered by AI Digital Twin Studio® creates a virtual replica of the Live Plant including Machinery, material handling, automation, assembly, kanbans, resources, shifts, and schedules.

Total Plant Visibility

Digital Twin Studio® provides real-time factory monitoring in 2D, 3D, and VR.

View the live plant with info on resources, material handling, equipment, change overs and product flow.


Manufacturing Digital Twin


Patented Data Integration

Digital Twin Studio® connects directly to your ERP/MRP. From there, your model loads actual data sets with 99.9% accuracy.

manufacturing Patented Data integration

Gain Efficiency in Real-Time

AI performs predictive analytics on-the-fly. Digital Twin Studio® then presents solutions to increase efficiency that can be implemented instantly.

Part Routing


WIP Management

Cost per SKU

Machine Lifecycle


Proactive, Hands-Off Plant Management

Digital Twin models automate historical
analysis, improve current operations, and can
help plan for future expansion, all in real-time.


Manufacturing Digital Twin using Digital Twin Studio® represents a virtual replica of the actual manufacturing facility including all of its special constraints, equipment, process flows, batching, changeover and tooling. The Digital Twin performs similarly to the live operation, exhibits the same behavior when subjected to the plant constraints and accounts for both capacity and manpower constraints.

Data-Driven Manufacturing Digital Twin takes the implementation to the next level by allowing the Digital Twin to load actual data sets (Current and Historical) from the active ERP/MRP/SAP and generate both predictive and prescriptive analytics within the manufacturing facility based on scheduling, maintenance, and constraints. The Data-Driven Digital Twin enables you to analyze historical performance, improve current operations, mitigate risk, forecast expansion and optimize future operations.


Benefits of Data-Driven Digital Twin for Manufacturing

  • Schedule Analysis and Optimization
  • Identify & reduce bottlenecks and constraints in Real-Time
  • Real-time Automation analysis and material handling optimization
  • Capacity analysis and growth projection - Determine the Cost Per SKU
  • New and Existing plant design
  • WIP reduction and optimizations
  • Real-Time Visibility

manufacturing digital twin - Digital Twin Studio


With Digital Twin Studio®, you can Model, Analyze, Optimize and Visualize in Real-Time a section of the factory or the complete factory. The Factory Digital Twin contains all the factory detail including BOM, Assemblies, Equipment, Material Handling, Maintenance, and Raw Material. Using a patented multi-threaded analysis engine, Digital Twin Studio® is the tool you need to optimize your operation in Real-Time.

Digital Twin Studio® provides

  • Direct connectivity to ERP/MRP/SAP systems
  • Built in features to model, analyze and optimize all aspects of the manufacturing including production line, assembly line, packaging line and process flow
  • Fully interactive, Low-Coding Dashboarding environment
  • Accurate Digital Twin Modeling with 99.9% accuracy
  • Built in Value Stream Mapping and Lean Analysis

Digital Twin Studio® ROI

  • Obtain integrated reporting and scenario analysis
  • Gather feedback on efficiency gains both at the machine and resource level and throughout the system
  • Predict how operations will be affected by: changes in demand, disruptions in supply, changes in the product mix, etc
  • Check and set optimal schedules
  • Establish the best path for production to increase productivity and reduce non value-added time
  • Analyze possible differences in efficiency based on automation versus manual labor

I would like to learn more about Digital Twin Studio® and Real-Time Predictive Analytics.

Package Options

Choose your Factory Digital Twin Implementation

Price is per license per month. One license per facility.
Ongoing support is included with any active subscription.

Digital Twin Studio - Created by CreateASoft

Digital Twin Studio® Tracker


  • Live Facility View in 2D, 3D, & VR
  • Hourly Event Replay
  • Direct Connection to Live Data:
  • Call for Price

Digital Twin Studio® Analyzer

Digital Twin Studio® Tracker, plus:

  • Heat Maps
  • Spaghetti Diagrams
  • Congestion Analysis
  • Full Historical Replay with Simulation
  • Call for Price

Digital Twin Studio® Optimization / AI

Digital Twin Studio® Analyzer, plus any combination of the following AI Modules

  • Part Routing Optimization
  • WIP & Kanban Optimization
  • Storage Density Optimization
  • Scheduling Optimization
  • RFID/RTLS live tracking with SmaRTLS®

All Modules include Dynamic Alerts and Notifications

  • Call for Price