The use of digital twins in the manufacturing industry is progressing, and there are reports of great results. What kind of benefits can digital twins bring to the manufacturing industry? We will introduce the reasons why digital twins are attracting particular attention in the manufacturing industry, their benefits, and examples of their use in the manufacturing industry.
The meaning and application of digital twin
Let's start by taking a look at an overview of what a digital twin is.
What is a Digital Twin?
A digital twin is a virtual reproduction of an object in the real world, a digital model that looks just like the real thing. Using this "digital twin," real-world objects and events are controlled digitally. The purpose of using digital twins is to analyze the data obtained and feed it back into the real world for ideal operation and management. For more information about digital twins, please also see " What is a digital twin? Introducing the benefits and examples of connecting the virtual and real worlds ."
Digital Twin Applications
Digital twins are increasingly being used in a variety of fields. They are used in a wide range of industries, including manufacturing, construction, logistics, and infrastructure, for factories and products, urban planning, construction planning, and store operations. Data collection using sensors is essential for the introduction of digital twins. With the development of sensors, it is now possible to obtain biometric data not only from machines, but also from people. In addition, by combining this with image processing technology, it is possible to digitize people's movements and behavior patterns. As the development of sensors has made it possible to reflect a variety of data in digital twins, the introduction of digital twins is progressing in many fields.
Why digital twins are attracting attention in the manufacturing industry
Digital twins are being used in a variety of fields and are expected to be effective, but there are especially high expectations for their use in the manufacturing industry. Digital twins are not a new concept, and the idea has been around since the 1960s. However, it was the realization and spread of IoT and the Industry 4.0 policy advocated by the German government that triggered digital twins to attract significant attention in the manufacturing industry. How did each of these factors lead to digital twins?
Realization and spread of IoT
In the past, only some machine operations in manufacturing could be digitized, but the majority of work was not. Sensors and networks for collecting data in real time were not in place, making it impossible to utilize the data. IoT has dramatically changed this situation. In an IoT-enabled environment, sensors can be attached to everything and connected to a network, making it possible to collect data in real time.
With the spread of IoT, actions and changes that were previously only handled by sensation or recording can now be visualized as real-time data. This makes it possible to reflect real-world events digitally. It can be said that the realization and spread of IoT was a major catalyst for digital twins reaching a practical level.
Industry 4.0
Industry 4.0 is an industrial policy proposed by Germany in 2011. Mass production through the application of steam engines, mechanization through oil and electricity, and automation through the application of IT are positioned as the first to third industrial revolutions. Industry 4.0 is described as the fourth industrial revolution that follows these. Industry 4.0 is said to be a state in which things, people, and systems are interconnected through real-time data collection and its use, and production lines are autonomous. Six technologies were listed as necessary to realize this major industrial transformation.
One of them was the digital twin. Industry 4.0 attracted the world's attention. At the same time, the digital twin also attracted attention. When IoT was introduced into the manufacturing industry, the idea of a smart factory where everything in the factory is connected to the Internet and real-time data collection was born. The digital twin is a further step beyond the smart factory and embodies data utilization. Digital twins have become known around the world for their use in the manufacturing industry, and are expected to be a new form of factory management.
Benefits of using digital twins in manufacturing
Digital twins have attracted attention mainly for their use in the manufacturing industry, and have a high affinity with the manufacturing industry. In what ways are manufacturing and digital twins deeply connected? Let's take a look at the benefits of using digital twins in the manufacturing industry.
Quality improvement through data analysis
Digital twins are "digital twins" that exist in the virtual world, so even if an error occurs when they are operated, there is no loss in the real world. This makes it easy to repeat trial and error. In addition, data collected from everything in the factory can also be used for traceability. This type of data analysis makes it possible to identify and correct the cause of errors, leading to improved product quality.
Shortening development processes and prototype times, and reducing costs
Development in the real world requires consideration of complex interrelated factors, such as whether production is possible with existing facilities and personnel, and whether delivery can be made within the deadline. In addition, it is often necessary to make prototypes in between production plans, send them to related departments or business partners for confirmation, and then make prototypes again. Digital twins enable testing without these real-world constraints, shortening the development process and prototyping time. This also reduces development costs.
Improved operation status through predictive maintenance
By analyzing data collected by digital twins, it is possible to detect signs of trouble in facilities and equipment, predict the cycle of part deterioration, and more. The analysis results make it possible to carry out predictive maintenance, such as repairing equipment when signs of trouble appear before it breaks down, or replacing deteriorated parts before problems occur. In addition, since maintenance work can be carried out with ample time rather than taking emergency measures such as repairing equipment after it breaks down, the number of times machines are stopped can be reduced. This improves operating conditions and increases productivity.
Remote operation is possible, making it possible to standardize technical capabilities
With a digital twin, you can grasp the situation even if you are not on-site, and you can operate the plant or deal with problems remotely. Highly skilled engineers can check the digital twin and give instructions and advice on how to deal with the problem from a remote location, allowing for early recovery when a problem occurs. Digital twins can also be used for education and training from remote locations. This type of use makes it unnecessary to assign highly skilled personnel to each base, and also makes it possible to standardize technical capabilities through information sharing and education.
Digital twin use cases in manufacturing
Many companies in the manufacturing industry are moving forward with the introduction of digital twins. Here are some examples.
Predicting the future with digital twins to obtain optimal solutions
Hitachi, Ltd. collects all kinds of data from actual production sites, models them as digital twins, and uses them for traceback and simulations. Since it is possible to accurately track raw material lots, parts used, and product movements, in the unlikely event of a defect, a swift and appropriate recall system can be put in place. This creates a mechanism to prevent the problem from escalating into a large-scale recall. In addition, by aggregating data from the production line into a digital twin and managing it centrally, product management and quality evaluation are also easy. With an accurately reproduced digital twin, it is also possible to predict the future through data analysis and use it to derive optimal solutions.
Digital twins solve problems in physically separated production sites
Kawasaki Heavy Industries, Ltd. has built a digital twin of its factory and is using it to manage production lines and manufacturing sites. This allows for rapid response when production equipment malfunctions occur, and predictive maintenance is also possible through data analysis. In addition, experts can be consulted remotely at multiple bases, shortening the time it takes to identify the cause of a problem from past data. One of the strengths of digital twins is that they can be used to see not only the past and present, but also future operating conditions and potential problems.
Digital twin enables traceability down to the individual item
Suntory Beverage & Food has built a digital twin in a factory equipped with an IoT environment and is using the digital twin for production management. Abnormal predictions are visualized on the digital twin, and defects can be tracked down to individual products, realizing a flawless traceability system.
Managing plants and dealing with problems with digital twins
Asahi Kasei Corporation has introduced a digital twin at its hydrogen production plant, establishing a system for distributing technical capabilities to remote locations. Process control at chemical plants is difficult to document in manuals how to respond when an abnormality occurs, and it is not rare that a veteran engineer must respond. However, it is difficult for a limited number of veteran engineers to manage all the equipment, and they may be absent due to holidays or business trips. Therefore, by utilizing a digital twin, it is now possible to check the on-site situation from a remote location and to give instructions on how to respond. In the future, the company plans to expand this to support overseas plants as well.
Digital twins becoming more prevalent in manufacturing
We introduced the reasons why the use of digital twins in the manufacturing industry is attracting attention, the benefits of using them, and examples of their use that have already been introduced. Digital twins have attracted global attention due to the realization of IoT and Industry 4.0, and are rapidly becoming more widespread in the manufacturing industry. By using digital twins, prototyping, testing, development processes that were previously carried out at actual manufacturing sites can now be carried out digitally, reducing risks and improving quality. In the future, digital twins will become an indispensable part of the manufacturing industry, and many factories may have their own "digital twins" as the core of efficient operations.
Reference article:
What is Industry 4.0? Explaining the current situation and challenges in Japan, and the key points to realizing it | Stratus Blog
