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Manufacturing Digital Twins Ebook Final
Manufacturing Digital Twins Ebook Final
1 Executive Summary
7 Conclusion
Digital transformation, together
Next steps
Temperature:
1,000 degrees
Oxygen: 15%
Fans: Off
The term ‘digital twin’ is believed to be
Digital twins deliver agility in coined by Dr. Michael Grieves during a 2002
Digital twins deliver agility in presentation on product optimization within
manufacturing Product Lifecycle Management. During his
manufacturing presentation at University of Michigan, he
spoke of a “management center” that held
A digital twin is… insights on real space and virtual space,
facilitated the sharing of data and
information between the two. v
Digital twins are virtual replicas of physical
Used in conjunction with IoT, today’s digital
assets and, even though there are many
twins unlock the abilities Grieves envisioned:
applications for the technology, twins share monitor and manage production remotely,
a common implementation pattern. Twins gain invaluable information for both real-
are built using computer-aided design time decision-making, strategic planning,
(CAD), bill of materials, simulation models, and energy cost-savings, time reduction,
IoT sensors, time-series data, maintenance operational efficiency, and innovation.
records, and any other data a manufacturer
wishes to bring together. The data is then
By 2022, Gartner expects 85 percent of
managed, unified, and modeled to build a
all IoT platforms will include some digital
high-fidelity digital representation of the
twin monitoring, and a few cities will take
physical reality.
the lead in showing the utility value of
Once modeled, a visualization layer provides digital twin smart city technology. xvii
insights, easy consumption, interaction, and
manipulation. This enables users to
A recent issue of the MIT Sloan
predicting failures, assess future
Management Review discussed the power
performance, and provide opportunities for of IoT and digital twins, “Supported by an
optimization. Digital twins are further able to estimated 25 billion connected global
integrate with artificial intelligence, machine sensors by 2021, digital twins will soon exist
learning, and analytics to create living for millions of things. A jet engine, a human
simulation models that change in tandem heart, even an entire city can all have a
with their physical counterparts. iii digital twin that mirrors the same physical
and biological properties as the real thing.
The implications are profound: real-time
Greater agility is critical in assessments and diagnostics much more
today’s market precise than currently possible; repairs
literally executed in the moment; and
Demand uncertainty and disruptions are innovation that is faster, cheaper, and
taxing planning systems to the brink and more radical.” vi
manufacturers are no longer able to depend The promise of Digital Twins, and the agility
on statistical forecasting models and scale they offer, is driving the technology in to
economies of mass production. With change the mainstream for manufacturers. Gartner
the only constant, it is no wonder that a reports that the digital twins market last
recent report by the United Nations year (2019) was USD 3.8 billion and is
Industrial Development Organization expected to grow to USD 35.8 billion,
(UNIDO) said it is critical that manufacturers ~10x increase, by 2025, at a CAGR of
37.8 percent. Vii
adopt supply-chain wide technology that
supports greater agility. ii
Digital Twins mean
“…digital twins give you the
moving faster
power of prescience to re-write
Technology has always made it possible to the future of your business.”
move faster, see things sooner and make
better decisions. The potency of an – Çağlayan Arkan, Vice President,
IoT/Digital Twins mix is that it creates a new Manufacturing Industry, Microsoft
digital feedback loop for manufacturers. As
connections and communication between
products, assets and processes become In a recent study Gartner found that, while
more ubiquitous, the opportunity to use only 25% of manufacturers recognized
data to further automate, up-level, innovate Digital Twin as an important emerging
increases drastically. technology, many were utilizing digital twin
Feedback loops foster exponential learning technology without even realizing it.
and adaptability. “We see a world in the not- That’s ok and is often the case with
too-distant future where every business is emerging technologies, “digital twins give
powered by these digital feedback loops and you the power of prescience to re-write the
it becomes a normal part of doing business,” future of your business…from empowering
Sam George, Corporate Vice President of the remote, intelligent operations to ensuring
Azure IoT Engineering Team said in a recent business resiliency, to enabling the agility to
article, “companies that aren’t powered by predict and respond to real-time changes, ”
digital feedback loops will find themselves at says Çağlayan Arkan, Vice President,
a competitive disadvantage.” Manufacturing Industry, Microsoft.
While new technologies often feel out of
reach, digital twins are not for most. Believe
it or not, many companies actually use
applications supported by digital twin-like
capabilities to function right now.
Digital
Feedback
Loop
The path for every forward-thinking
manufacturer is to incrementally transition
from sparingly or unknowingly using digital “Azure Digital Twins gives you
twin-like technology to using it in strategically the ability to model anything,
in different phases of a process or lifecycle.
Manufacturers can start in very specific, very
create a live digital replica to
limited scenarios that provide the most control the present, track the
business value, long- or short-term, that past, simulate possibilities and
makes sense and then expand as new
opportunities become apparent.
predict the future.”
– Sam George, Corporate Vice
Real-world transformation President, Azure IoT, Microsoft
through Digital Twins
particularly compelling transformational
The potential of digital twins is only stories in different areas of manufacturing.
limited by the type of data that is available. 1. Remote control and communication
It is one thing to talk about it, it is another at Unilever
thing entirely to show it.
2. Rewind and Replay for “What If?”
There are many incredible stories in this Scenarios with thyssenkrupp
paper, but the next section highlights four
3. Serialized Asset Tracking and
Monitoring with Rolls-Royce
4. Digital Verification and
Validation with V4i
Remote Control and In fact, operators on the floor now trust the
Communication with Unilever twin more than themselves to monitor
settings like soap moisture levels and batch
The Marsden Group, a Microsoft Partner, process efficiency for optimal productivity.
delivered this key capability to Unilever, the Unilever Chief Engineer Dave Penrith says
manufacturer of products like Dove, “The more data it gets, the more it learns.
Vaseline, and Ben & Jerry’s. The more it learns, the faster it learns,
Using Azure IoT Edge and Azure Industrial and it starts to learn at an increasingly
IoT Platform capabilities, Marsden’s TwinIQ exponential rate.”
solution provides Digital Twin and Optimiser As a result, Unilever has digitized their
accelerator frameworks for the rapid factories to a point where not only are they
discovery and enablement of digital able to run them lights out, but also pivot
transformation. production almost immediately from making
The twin leverages huge volumes of data ice-cream to making hand sanitizers. This is
from factory equipment to build a digital a remarkable example
model. It learns and improves in real-time of a customer experiencing the benefits of
with AI and ML capabilities while enabling end-to-end digital transformation.
real-time data intelligence sharing,
conversation, and collaboration.
Remote connectivity gives Unilever Link to Partner
employees the ability to hand over control
of specific operations to the digital twin Link to full story
optimiser.
Humidity
twins to monitor,
optimize, and control
production processes
monitor processes and patterns, and rapidly
Rewind and Replay for “What identify problems using ‘what if’ simulations
If?” Scenarios with thyssenkrupp for fire evacuation and other emergency
management scenarios.
thyssenkrupp collaborated with Willow and
Microsoft to create a digital twin of These critical insights help thyssenkrupp
thyssenkrupp’s 246-meter Innovations Test improve elevator maintenance and be
Tower. Part of the project was to experiment proactively responsive to critical
with elevator technology, creating a building emergencies. From a building maintenance
design that reduces space lost to traditional perspective, the same twin can provide
rope elevators to free up more livable real visibility into maintenance needs and the
estate. The other part was to help real estate capability to rewind and replay if something
owners and managers reduce costs and goes wrong in the building infrastructure.
increase tenant satisfaction. The Willow Twin, and projects like it,
promise to open new possibilities for smart
With that in mind, the team created “Willow architecture and for remedying social
Twin,” a digital replica of the building challenges like overcrowding.
supported by Microsoft Azure. This is a twin
of an entire building. It generates analytics
on the elevator around different use
scenarios and collects real-time data on the
ways both staff and guests utilize not just
the elevator, but the entire building space
over the course of a day. Digital twin
analytics and intelligence replay enables Link to Partner
real-time connectivity of both people and Link to full story
data-driven systems across the building to
Rolls-Royce has
enabled serialized
tracking of assets
in-flight
With design cycle times and prototyping
Digital Verification and costs being what they are, digital twins offer
Validation with V4i a sound alternative to better physical
testing and validation while cutting cost.
Reducing or removing the need to Digital twins also provide a protected way
prototype is would be a game-changer for to mitigate risk and verify the safety and
most, if not all, manufacturers. V4i is a functionality of autonomous functions.
private-public consortium managed by the Digital verification and validation saves
National Center for Defense Manufacturing both time and money and creates new
and Machining (NCDMM) and is on a opportunities for agility in future
mission to provide advanced assurance in product design processes.
product development and manufacturing.
As a founding member of the consortium,
Microsoft enables a cloud-based, high-
performance computing and collaborative
design environment for manufacturers to
conduct multi-physics simulations and
systems modeling across the value-chain.
By leveraging the Azure platform, Microsoft
and V4i helps manufacturers develop trust
in their digital models and enable virtual Link to Organization
verification and validation of their designs.
• Unlock immediate value through quick “As manufacturers think about building agility
digital twin construction and integration into their supply chains, there is increasing
with ERP data. realization that these efforts cannot occur in
• Bring digital twin insights to first-line workers isolation,” states Deloitte’s 2020
to collect second order insights as part of a Manufacturing Industry Outlook. “The need
behavioral data feedback loop. to cultivate a strong ecosystem is a trend that
• Connect data with AI to determine solutions
has emerged, and our research shows that it
for specific use cases. is an increasingly effective strategy for
manufacturers, especially as it relates to
• Increase operational efficiency. digital momentum.”
• Secure consistency in packaging and shipping. In line with that, Microsoft has been taking
• Build trust with supply chain partners part in a multi-year collaboration of industry
and customers with an optimized leaders (e.g. OPC Foundation) and has
fulfillment process. adopted an open standard for exchanging
information in a rich, object-oriented, and
secure way. OPC Unified Architecture (OPC
UA) is the industrial interoperability standard
that scales from sensor to cloud.
It facilitates the creation of semantically rich
information models and provides secure data Our SI partners like Accenture, Capgemini,
exchange between industrial equipment and EY, Sigma, and Infosys also have deep
systems, including discovery as well as expertise in the digital twin space. Microsoft
command & control. It is open source, cross-
platform, vendor-neutral, and supports also actively partners with emerging
companion specifications/ extensions to other companies and niche startups in this space
industrial standards like BACnet, MTP or MT like Majik, Jitsuin, Datanomix, Supply Chain
Connect. Wizard and DeviceTone.
Of course, there are many others who are
ready to support your digital transformation
Conclusion no matter what stage or region you’re in.
Together, we can unlock entirely new
business models that support continuous
agility, advanced productivity, and ongoing
Digital transformation, together innovation.
Machine Operator
Quality/
Lab Data
Energy Process/
Data
Sight Machine
Ops Engineer
on Azure
Location
BlueYonder Data Platform Customers, Distributors, Retailers
Data
Location
Data
In-house developed Custom Enterprise Enterprise
Systems
systems Systems
Configuration management: Customer Story
management is correctly represented and
Featured Partner: Aras
has digital thread traceability. Aras
As a manufacturer of a wide range of Innovator now serves as the global
electronics and systems, Microsoft manages backbone at the heart of Microsoft's PLM
vast amounts of product data. Everything implementation. Microsoft is now in a better
from Surface computers, XBOX consoles and position to accelerate the latest devices to
HoloLens headsets to the servers, storage market due to Aras’s innovative approach
and networking in the Azure data centers to PLM.
around the world. When the Microsoft
Device Group needed to unify the product Aras helped Microsoft:
data from multiple business lines into a
single system, Microsoft turned to Aras and
• Align and unify fragmented systems
their Aras Innovator low-code platform.
supporting critical tasks such as the
To achieve the necessary collaboration and global product development, prototype
remote management required, Aras was testing, and supplier quality.
deployed on Azure. Aras Innovator has
• Connect and trace each product’s digital
proven to be an open and resilient platform
for PLM processes and much more, just what assets – and their revisions over the
Microsoft was looking for to support its lifecycle – including versions of BOMs,
global ecosystem of design partners and parts, software, electronics, CAD models,
contract manufacturers. Aras enabled the documents, manuals, and more.
rapid delivery of highly flexible, upgradeable • Support complex analysis of
solutions to manage the complex product configuration management, including
variants for engineering, manufacturing, and variants and options, with “closed-loop”
supply chain operations. traceability to verify requirements.
Aras helps ensure that critical product
information vital to configuration
Operations
• IoT feeds
4D
• Sensors
Timeline of
• Drones
Change
• Cameras
• LiDAR
• Point clouds
Information AI/ML
Analytics
• Asset tags Visibility
• Work orders
• Maintenance
records
• Inspection
records iTwins are continuously updated with data from the physical asset. This data is used to
understand and model the asset's performance.
References
• ii https://www.forbes.com/sites/lanceeliot/2020/04/14/apollo-13-has-its-50th-anniversary-
and-divulges-hidden-warning-signs-applicable-to-todays-ai-systems-including-self-driving-
cars/#7219f6be554c
• iii https://www.aiscorp.com/en/blog/entry/overcoming-the-top-5-manufacturing-
productivity-pain-points#_ftn1
• iv https://info.microsoft.com/rs/157-GQE-
382/images/Microsoft%27s%20Digital%20Twin%20%27How-To%27%20Whitepaper.pdf
• v https://www.gartner.com/en/newsroom/press-releases/2019-02-20-gartner-survey-reveals-
digital-twins-are-entering-mai
• vi https://www.challenge.org/insights/digital-twin-history/
• vii https://sloanreview.mit.edu/article/how-digital-twins-are-reinventing-innovation/
• ix https://www.howden.com/en-gb/digital-solutions
• x https://www.ansys.com/blog/designing-electric-car-battery-pack-pikes-peak-world-record
• xi https://azure.microsoft.com/en-us/blog/microsoft-partner-ansys-extends-ability-of-azure-
digital-twins-platform/
• xii https://www.ptc.com/en/product-lifecycle-report/digital-twin-howden-demo
• xiv https://www2.deloitte.com/us/en/pages/energy-and-resources/articles/manufacturing-
industry-outlook.html
• xv https://www.mtconnect.org/
• xvi https://thenewstack.io/the-digital-feedback-loop-powering-next-generation-businesses/
• xvii https://futuristspeaker.com/technology-trends/seven-ways-digital-twins-will-affect-your-
life-in-2028-and-beyond/
• xviii https://www.challenge.org/insights/digital-twin-and-iot-platforms/
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