- Predictive maintenance, process optimisation, cost reduction and improved decision-making are just some of the advantages offered by the use of digital twins.
A digital twin is a precise and dynamic virtual replica of an object, system or process, which is kept synchronised through real-time data in order to predict failures, optimise performance or assist in decision-making without causing any disruption.
The simulation, monitoring and analysis capabilities offered by digital twins, while not exclusive to the world of Industry 4.0, are highly relevant to this sector.
Characteristics of digital twins
Supported by technologies such as AI, machine learning and data analysis, digital twins have a number of defining characteristics.
On the one hand, real-time synchronisation and connectivity to continuously update data from sensors located on the physical asset in question. This accurately reflects its current status.
In addition to this synchronisation, there is also the capacity for simulation and analysis to test different scenarios, develop simulations and analyse the performance of hypothetical changes before implementing them in the real world. To do this, data-driven decision-making is essential.
Another feature of digital twins is modularity, understood as the ability to break down complex assets into smaller parts or layers, which facilitates analysis and, therefore, improvement of the linked physical asset.
Main benefits of digital twins
The use of digital twins adds value in different ways.
On the one hand, from a predictive maintenance perspective, it is useful in anticipating possible failures or breakdowns in physical equipment. This reduces downtime, with the consequent impact on minimising economic losses linked to these periods of production stoppage.
On the other hand, digital twins also serve to optimise processes, improving operational efficiency and reducing waste of resources.
In terms of design and/or innovation, digital twins enable virtual testing and simulation to be carried out safely and at low cost.
Another feature of this technology is the continuous visibility of assets thanks to real-time traceability and monitoring, which facilitates quality management in products or processes.
All these factors lead to more accurate decision-making, with the operational and strategic benefits that this entails.
Example of a digital twin for industry
At the 2023 Mobile World Congress (MWC), Telefónica gave a demo of its technological capabilities to improve the production of industrial parts through a digital twin with the ability to make its own decisions in real time thanks to technologies such as 5G, machine learning, and edge computing.
The demo virtually recreated an industrial process to perform simulations that would make the manufacturing model more efficient and help detect possible faults in the manufacture of parts, generating actions to guarantee their quality.
In short, the creation of accurate virtual replicas of physical assets allows industry—but also other sectors—to monitor in real time, perform advanced simulations, or carry out predictive maintenance to improve operational efficiency by making data-driven decisions.
