1. Digital Twins Complement Human Expertise
Contrary to the belief that digital twins will replace human decision-making, they are designed to enhance it. While they can automate some decisions, their primary role is to provide data-driven insights that inform human decision-makers. For instance, in a packaging plant, digital twins can simulate production line changes, allowing engineers to optimize processes without disrupting operations.
2. Incremental Implementation is Effective
A complete overhaul of existing systems is unnecessary when adopting digital twins. Many companies successfully implement them incrementally, starting with a single component or process. This phased approach allows organizations to realize immediate benefits and gradually expand their digital twin applications. A production manager might begin with a digital twin for a single machine, then scale up to include the entire production line.
3. Data Quality Can Improve Over Time
Perfect data is not a prerequisite for developing a digital twin. Companies can begin with the data they have and enhance its quality over time. This approach is particularly useful for facilities transitioning from manual to digital data collection. For example, a quality control specialist might initially use existing inspection records to create a digital twin, refining the data as more accurate digital inputs become available.
4. Beyond Equipment: Diverse Applications
Digital twins are not limited to machinery. They can be applied to entire systems, such as supply chains or quality control processes. This versatility allows for comprehensive monitoring and optimization across various operational areas. A systems engineer might use a digital twin to simulate and improve the efficiency of a packaging facility's logistics network, reducing bottlenecks and improving delivery times.
5. Cost Overruns Are Not Inevitable
Concerns about digital twin implementation costs are often overstated. Surveys indicate that cost overruns are not a predominant issue, ranking low among implementation challenges. Companies can manage expenses effectively by carefully planning and executing digital twin projects. An operations manager might allocate resources strategically, ensuring that each phase of digital twin deployment stays within budget while delivering measurable value.
This report used data from Hexagon’s Digital Twin Value-Maturity survey, which surveyed 660 C-level executives and their direct reports about the adoption of digital twin technology within their organizations. To download the report visit here.
