MANUFACTURING DIGITAL TWIN

DIGITAL TWIN STUDIO^®

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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

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

Real-Time Visibility

Benefits of Data-Driven Digital Twin

Advantages of a Data-Driven Digital Twin™ for Manufacturing:

Boost manufacturing Efficiency - Refine Facility Layout and Design

Optimize Production Layout: Design your production layout to minimize travel time and streamline the flow of goods.
Implement Lean Practices: Adopt lean manufacturing principles to eliminate waste and improve processes. This includes reducing unnecessary movements, optimizing inventory levels, and continuously improving workflows.
Use Technology: Live Connectivity to current systems, PLC / ERP / MRP / WMS / WES / SAP and more.
Enhance Inventory Management: Regularly review and update inventory practices to ensure accuracy and reduce stock outs or overstock situations.
Improve Order Picking: Streamline the order picking process by using methods such as batch picking, zone picking, or wave picking.
Train and Empower Employees: Provide regular training to employees on best practices and new technologies.
Monitor Performance Metrics: Track key performance indicators (KPIs) such as order accuracy, inventory turnover, and picking efficiency.

Optimizing production Design to Reduce Congestion

Strategic Layout Planning: Design the layout to minimize bottlenecks and ensure smooth flow of goods.
Implementing Advanced Technologies: Use automated systems like Automated Guided Vehicles (AGVs) and Autonomous Mobile Robots (AMRs) to streamline material handling and reduce human traffic.
Dynamic Routing Systems: Incorporate dynamic routing algorithms that can adjust paths in real-time based on current congestion levels.
Regular Traffic Analysis: Conduct regular traffic flow analysis to identify and address congestion points.
Efficient Scheduling: Stagger work shifts and schedule deliveries during off-peak hours to avoid congestion.
Employee Training: Train employees on best practices for material handling and traffic management. Empower them to identify and report congestion issues.

Improve Material Handling and Fleet Sizing while Conducting Distribution Center Network Analysis

Create a Digital Twin: Develop a virtual model of your warehouse using digital twin technology. This model should replicate the physical characteristics and behavior of your warehouse, including layout, equipment, and workflows.
Simulate Material Handling Processes: Use the digital twin to simulate various material handling processes. This includes the movement of goods, the interaction between different systems (e.g., conveyors, AGVs), and the flow of materials through the warehouse.
Analyze Fleet Sizing: Determine the optimal size and configuration of your material handling fleet. The digital twin can help you simulate different fleet sizes and configurations to find the most efficient setup for your operations.
Conduct Network Analysis: Use the digital twin to perform a comprehensive analysis of your distribution center network. This includes evaluating the placement of distribution centers, the flow of goods between them, and the overall efficiency of the network.
Optimize Layout and Design: Continuously refine the layout and design of your warehouse based on insights gained from the digital twin.
Implement Real-Time Monitoring: Integrate real-time data from sensors and IoT devices into the digital twin.
Scenario Testing: Use the digital twin to test various “what-if” scenarios.

Enhance ASRS, AGV, and STV Capacity Planning to Validate and Design Automation Systems

Bottleneck Identification - Use simulation data to pinpoint bottlenecks in the production line. Optimize task sequencing to minimize downtime. Implement targeted improvements to alleviate bottlenecks.

Process Flow Analysis - Visualize and evaluate the entire production process flow. Identify non-value-added activities and streamline processes. Enhance overall process efficiency and productivity.

Performance Metrics - Track key performance indicators (KPIs) such as throughput, cycle time, and utilization rates. Compare simulated performance against benchmarks and goals. Use data-driven insights to guide decision-making

Package Option

Choose your Manufacturing Digital Twin Implementation Price is per license per month. One license per facility. Ongoing support is included with any active subscription.

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3909 75th St. Ste 105,
Aurora, IL 60504
(630) 851-9474
(630) 566-0756

ABOUT US

With over 30 years of industry experience, we are proud to support over 3,600 clients worldwide, helping them achieve sustainable competitive advantages through advanced digital twin technology.

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