Digital Twin Manufacturing

A Factory 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.


A Data-Driven Factory 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
  • Automation feasibility analysis and material handling optimization
  • Capacity analysis and growth projection
  • Greenfield, Brownfield analysis and design
  • WIP reduction and optimizations 
  • Expand Visibility



With Digital Twin Studio®, powered by Simcad Pro®, you can model, analyse and visualize the complete factory digital twin, from receiving to shipping, in Real-Time. The integrated patented multi-threaded engine utilizes machine learning and AI to perform predictive analytics, optimization and insights into the operation.


Digital Twin Manufacturing provides

  • Live tracking through digital twin shadow in 2D, 3D and VR.
  • Live analytics, dashboarding and alerts.
  • Direct connectivity to ERP/MRP/SAP systems.
  • Dynamic optimization and predictive analytics.
  • 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, no coding interface for quick model building and validation.
  • Accurate digital twin modeling with 99.9% accuracy.
  • Built in Value Stream mapping and lean analysis.

warehouse analysis and optimization

Digital Twin 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.