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Cloud Digital Twin Ebook en
Cloud Digital Twin Ebook en
ADVANTAGES OF DIGITAL
TWIN FOR MANUFACTURERS
Unlimited Iterations
Better Insight
Improved Human Factors
Added Flexibility
Global Connectivity
Sensor Integration
Knowledge Retention
IS MY BUSINESS RIGHT
FOR A VIRTUAL TWIN
EXPERIENCE?
1
INTRODUCTION
ADVANTAGES OF DIGITAL
TWIN FOR MANUFACTURERS
Unlimited Iterations
Better Insight
Improved Human Factors
Added Flexibility
Global Connectivity
Sensor Integration
Knowledge Retention
INTRODUCTION
VIRTUAL TWIN EXPERIENCE
In manufacturing, bigger is better. In the 20th century, that truth Digital renderings of component parts, assemblies and fixturing
FOUR STEPS TO SUCCESSFUL
was self-evident: economies of scale and lower unit costs were are nothing new to 21st century manufacturers. Today, even small VIRTUAL TWIN EXPERIENCE
proportional to the production run, and this spawned some of the operations use integrated CAD/CAM systems and G/M-code to program REALIZATION
most famous industrial concerns of the century, such as VW, Toyota production equipment—everything from multi-axis machining centers IS MY BUSINESS RIGHT
and General Electric. to pick-and-place robotics. FOR A VIRTUAL TWIN
EXPERIENCE?
In the 21st century, however, the manufacturing landscape is changing. This digitalization of the workplace, however, has been ad hoc and A VIRTUAL TWIN EXPERIENCE
Tools and technologies formerly restricted to large operations are distributed. Design, manufacturing, production planning and MRO WILL BOOST MYBUSINESS;
CAN YOU CREATE IT FOR ME?
becoming more affordable and accessible to small and medium- frequently operate as independent “silos” within the organization.
sized manufacturers. Large manufacturers traditionally had scale But what if this data could be aggregated and expanded to allow total
I’VE IMPLEMENTED
advantages in computing, while smaller companies were limited to process simulation of an actual production process? The potential for A VIRTUAL TWIN EXPERIENCE.
the power of their computers and knowledge. new insight into operations is obvious, and it’s used every day in large HOW DO I KNOW IT’S WORKING?
2
INTRODUCTION
ADVANTAGES OF DIGITAL
Proactive flexible production TWIN FOR MANUFACTURERS
Prashanth Mysore
Director of Global Strategic Business VIRTUAL TWIN EXPERIENCE
Many use special assembly lines to test innovation, but most I’VE IMPLEMENTED
A VIRTUAL TWIN EXPERIENCE.
manufacturing enterprises are smaller. These smaller enterprises HOW DO I KNOW IT’S WORKING?
simply can’t afford to suspend production in order to experiment
with new technology or line configurations. A digital twin of the
production process allows those companies to test, alter and test
again—virtually.
3
INTRODUCTION
ADVANTAGES OF DIGITAL
TWIN FOR MANUFACTURERS
Unlimited Iterations
Traditionally, there were two ways to improve a manufacturing FOUR STEPS TO SUCCESSFUL
VIRTUAL TWIN EXPERIENCE
process: analyze/implement or iterate/experiment. REALIZATION
4
INTRODUCTION
BETTER INSIGHT
ADVANTAGES OF DIGITAL
TWIN FOR MANUFACTURERS
Many profitable SME’s run at or near capacity, but when running
Unlimited Iterations
at full speed, where are the production bottlenecks? Is throughput
Better Insight
machine limited or human-determined?
Improved Human Factors
Added Flexibility
In fully automated assembly, it is easy to determine efficiency—
Global Connectivity
either the line runs at design speed, or it doesn’t. But in small and
Sensor Integration
medium-sized operations, automation is usually mixed with human
Knowledge Retention
workers. Are these workers deployed to compensate for production
bottlenecks? What happens if automated equipment runs faster?
VIRTUAL TWIN EXPERIENCE
Take machine tending, for example. A common use for CNC (Computer
Numerical Control) machine tools is part production from blanks FOUR STEPS TO SUCCESSFUL
VIRTUAL TWIN EXPERIENCE
or forgings. A human tender may load and unload one or multiple REALIZATION
machines on an assembly line, but a new machine may operate with
IS MY BUSINESS RIGHT
a faster cycle time. Can the tender keep up? Or will the human become FOR A VIRTUAL TWIN
the limiting factor in the system cycle time? EXPERIENCE?
5
INTRODUCTION
ADVANTAGES OF DIGITAL
TWIN FOR MANUFACTURERS
Unlimited Iterations
Better Insight
Enforcing social distancing is part of ensuring a safe workplace FOUR STEPS TO SUCCESSFUL
VIRTUAL TWIN EXPERIENCE
in the new normal. Manufacturers must evaluate how workers REALIZATION
move through the facility and identify potential areas where
social distancing won’t be possible. With a digital twin, they IS MY BUSINESS RIGHT
FOR A VIRTUAL TWIN
can create a safety envelope around each worker to simulate EXPERIENCE?
social distancing and the flow of worker movements through
the plant. As a result, manufacturers can adhere to health and A VIRTUAL TWIN EXPERIENCE
WILL BOOST MYBUSINESS;
safety regulations for workers regardless of country. CAN YOU CREATE IT FOR ME?
ADVANTAGES OF DIGITAL
TWIN FOR MANUFACTURERS
Unlimited Iterations
Better Insight
Improved Human Factors
Added Flexibility
Global Connectivity
Sensor Integration
Knowledge Retention
ADVANTAGES OF DIGITAL
TWIN FOR MANUFACTURERS
Unlimited Iterations
Better Insight
Improved Human Factors
Added Flexibility
Global Connectivity
GLOBAL CONNECTIVITY Sensor Integration
Knowledge Retention
It’s a global marketplace for manufacturers, but expertise has Similarly, shipping completed goods may be more cost effective if
traditionally been limited to what a professional could see for containerized. How would the goods be handled to consolidate full VIRTUAL TWIN EXPERIENCE
himself or herself on the shop floor. It is possible to share drawings container loads? Would additional warehousing space be needed?
and even video of operations with experts around the world, but Racking? Forklift access? These and many other considerations can FOUR STEPS TO SUCCESSFUL
VIRTUAL TWIN EXPERIENCE
illustrating what a line or process should be is more difficult. be tested with a digital twin before an expensive commitment is REALIZATION
approved.
IS MY BUSINESS RIGHT
A digital twin in a cloud-based hardware/software environment FOR A VIRTUAL TWIN
allows experts located anywhere to add useful insight into factory Cloud-based global collaboration carries security risks and good EXPERIENCE?
processes. Consultants, engineers from overseas divisions and platforms have security built into their code. According to Mysore,
A VIRTUAL TWIN EXPERIENCE
engineers working remotely can all contribute and demonstrate “That's a key differentiator of the 3DEXPERIENCE® platform on the WILL BOOST MYBUSINESS;
their ideas in animation, allowing senior managers to approve Cloud. The concept of “Security in Depth” at Dassault Systèmes CAN YOU CREATE IT FOR ME?
changes and try ideas with more input from more experts than relies on the fact that several independent mechanisms are put
would be possible through static CAD-based renderings. in place in order to mitigate any single risk and follows industry I’VE IMPLEMENTED
A VIRTUAL TWIN EXPERIENCE.
standards and best practices, where practical and applicable. When it HOW DO I KNOW IT’S WORKING?
Another advantage of using a digital twin is the ability to analyze comes to application security, the platform includes comprehensive
how changes to factors external to the production process affect access controls and authentication, including the availability of two-
productivity. For example, a common way to reduce cost in injection factor authentication. And all communications are done through a
molding operations is to use hopper loaders fed from a central resin secure sockets layer, transport layer security channels with 128-bit
storage tank. Vendors bidding on a major project to upgrade an encryption.”
in-plant distribution system could be invited to use the digital twin
to determine the proper equipment capacity and layout in the plant
before a site visit.
8
INTRODUCTION
ADVANTAGES OF DIGITAL
TWIN FOR MANUFACTURERS
Unlimited Iterations
Better Insight
SENSOR INTEGRATION Improved Human Factors
Added Flexibility
generates large quantities of data in real time. Much of this Sensor Integration
information is used for simple analysis for quality control or Knowledge Retention
ADVANTAGES OF DIGITAL
TWIN FOR MANUFACTURERS
Unlimited Iterations
Better Insight
Improved Human Factors
Added Flexibility
Global Connectivity
KNOWLEDGE RETENTION Sensor Integration
Knowledge Retention
Older manufacturing operations often have processes and Cloud by definition enables integrated data continuity; digital VIRTUAL TWIN EXPERIENCE
employees with vast amounts of institutional knowledge. Losing twin institutionalizes enterprise knowledge before this becomes a
key personnel has long been a problem for SMEs and this now problem and ensures continuity in the event of a key loss, whether FOUR STEPS TO SUCCESSFUL
VIRTUAL TWIN EXPERIENCE
extends to technology with storage formats becoming obsolete human or material. REALIZATION
and translation of code being difficult from legacy equipment.
IS MY BUSINESS RIGHT
FOR A VIRTUAL TWIN
EXPERIENCE?
I’VE IMPLEMENTED
A VIRTUAL TWIN EXPERIENCE.
HOW DO I KNOW IT’S WORKING?
10
INTRODUCTION
IS MY BUSINESS RIGHT
FOR A VIRTUAL TWIN
EXPERIENCE?
IMPROVE LEARN
•Capitalize •Enrich Data
R2V
•Improve Real Life Insights •Interpret Data in Context
Virtually Validated Continuously Updated
enrich the Design
•Predict / Prescribe •Formulate and Test Hypothesis
11
INTRODUCTION
others in a Virtual Twin Experience form. With the help of these IS MY BUSINESS RIGHT
catalogs, one can manually build the layout. If you think that FOR A VIRTUAL TWIN
EXPERIENCE?
scanning is a laborious affair, it isn’t anymore.
A VIRTUAL TWIN EXPERIENCE
WILL BOOST MYBUSINESS;
CAN YOU CREATE IT FOR ME?
Optimization is the payoff from the Virtual Twin Experience, the process
I’VE IMPLEMENTED
where changes are tested, tried virtually and tested again to reduce A VIRTUAL TWIN EXPERIENCE.
production bottlenecks and improve efficiency. This is where planning HOW DO I KNOW IT’S WORKING?
Collaboration is the process by which the different stakeholders in changes become true “what if” experimentation, iterating many changes
the manufacturing organization gather to work out the needs, wants in real time, from equipment cycles to worker time and motion study.
and goals of the overall project. Design engineering, manufacturing
engineering, quality assurance, sales, procurement and management all Performance is the goal of the digital twin, the actual implementation of
may have useful input into the creation of a unified system. the new processes and procedures worked out in the virtual factory. With
a successful the Virtual Twin Experience, production changes are swift,
Modeling is the starting point for digitalization. It is the rendering trouble-free and downtime is minimized. Sensor-equipped equipment then
of physical systems (and often humans, too) to create an accurate feeds real-time data back to the twin to confirm outcomes and establish a
representation of machines, processes and workflows. new baseline for the next series of experiments and improvements. 12
INTRODUCTION
IS MY BUSINESS RIGHT
FOR A VIRTUAL TWIN
EXPERIENCE?
Our customers value the
fact that we’re going to give A VIRTUAL TWIN EXPERIENCE
WILL BOOST MYBUSINESS;
them good equipment but CAN YOU CREATE IT FOR ME?
13
INTRODUCTION
IS MY BUSINESS RIGHT
ADVANTAGES OF DIGITAL
FOR A VIRTUAL TWIN EXPERIENCE? TWIN FOR MANUFACTURERS
Every major change in capital equipment or process in a manufacturing on a similar technology, it is an opportunity for SMEs to be on the same Unlimited Iterations
Better Insight
operation needs a strong business case, regardless of size. “What are we platform and learn from the new Virtual Twin Experience transformation
Improved Human Factors
trying to achieve here? What is the first business case?” Mysore states. products,” Mysore relates.
Added Flexibility
Global Connectivity
“Let's imagine the first business case of a Virtual Twin Experience is “That's a great opportunity for the supply chain, but we don't want
Sensor Integration
to optimize the efficiency of workers or to improve overall equipment to overload small and medium-sized enterprises with one ‘big bang’
Knowledge Retention
effectiveness. We need to define these kinds of use cases, and start to approach if they’re not ready for major transformation. Of course, they
implement small. They like the benefits, and then we add on more use may be instructed or requested by OEMs to be on a single platform.
cases. We enhance the basic digital twin with Virtual Twin Experience. Either way, we can help. Our cloud hardware/software environment VIRTUAL TWIN EXPERIENCE
It's not a static digital twin. Virtual Twin Experience is an executable helps SMEs on their individual digitalization journey, and also supporting
virtual model of a physical system which brings in learning and the OEM customers.” FOUR STEPS TO SUCCESSFUL
VIRTUAL TWIN EXPERIENCE
experiences taken from real-world processes to update the digital twin REALIZATION
model. SMEs can not only improve but unleash new business creativity
from a point of in-depth manufacturing knowledge. Achieving this IS MY BUSINESS RIGHT
FOR A VIRTUAL TWIN
closed-loop capability is the full realization of benefits to be gained EXPERIENCE?
from the convergence of the virtual and real worlds,” said Mysore.
A VIRTUAL TWIN EXPERIENCE
WILL BOOST MYBUSINESS;
“That's our approach, and then we also have a methodology called CAN YOU CREATE IT FOR ME?
value engagement. It gives all implementers, irrespective of size, a
roadmap for implementing a Virtual Twin Experience.” I’VE IMPLEMENTED
A VIRTUAL TWIN EXPERIENCE.
HOW DO I KNOW IT’S WORKING?
In essence, Mysore is describing a kind of recursive process, where the
act of implementing a Virtual Twin Experience helps small and medium
size firms with their implementation.
Unlimited Iterations
Dassault Systèmes recognizes that creating the Virtual Twin Better Insight
Experience can be a challenge for the customer in many contexts. Improved Human Factors
For instance, the time to implement software solution and train its Added Flexibility
employees is not compliant with a short business schedule, budget Global Connectivity
priorities are more on Services with short term results than on long- Sensor Integration
term investments, may be reasons to delay Digital Transformation Knowledge Retention
decisions.
VIRTUAL TWIN EXPERIENCE
Dassault Systèmes has developed an “Outcome-Based Services”
approach, which is reflected in the concept “We do it for you”: FOUR STEPS TO SUCCESSFUL
literally, our experts use our solutions to build the Virtual Twin VIRTUAL TWIN EXPERIENCE
REALIZATION
Experience, starting from 3D Scan and/or 2D drawings and pictures
of your facilities and equipments, and delivering best results you IS MY BUSINESS RIGHT
can directly apply within your projects. It secures short term results FOR A VIRTUAL TWIN
EXPERIENCE?
and benefits, and when you wish to operate our software solutions
by yourself, you get a ready to use environment with the Virtual A VIRTUAL TWIN EXPERIENCE
Twin Experience. WILL BOOST MYBUSINESS;
CAN YOU CREATE IT FOR ME?
16
INTRODUCTION
Unlimited Iterations
It’s a major step for an SME to implement leading-edge technology to It really comes down to simple principles. The backbone of manufacturing Better Insight
business-critical operations. The goal is always better performance, but is the small and medium-sized. Virtual Twin Experience on the cloud Improved Human Factors
how is this best measured? gives them a huge opportunity to optimize their business processes. Added Flexibility
Global Connectivity
According to Mysore, “I like to classify validating these KPIs or returns Sensor Integration
on investment into three buckets. The first one is in the resources Knowledge Retention
themselves. It can be equipment or manpower. Are we seeing an
improvement in uptime of a machine or productivity, or improvement
VIRTUAL TWIN EXPERIENCE
of effectiveness of a machine in between failures? Then the second
one is at the company level, or at the departmental level where we FOUR STEPS TO SUCCESSFUL
have a complete line utilization. Does it utilize one hundred percent? VIRTUAL TWIN EXPERIENCE
REALIZATION
Can we introduce multiple models? Can we do advanced configuration
management, and all those things on an existing line?” IS MY BUSINESS RIGHT
Mysore’s third “bucket” isn’t measurable a KPI, or MTBF. It’s intangible, FOR A VIRTUAL TWIN
EXPERIENCE?
but just as important as any metric. “It has all the ingredients for the
workforce of the future. For these younger workforce who want to A VIRTUAL TWIN EXPERIENCE
take up jobs in manufacturing, the 3DEXPERIENCE platform supports WILL BOOST MYBUSINESS;
CAN YOU CREATE IT FOR ME?
them. It's imaginative, immersive, collaborative, and predictive—all the
ingredients of what a younger workforce really expects. That's a key
I’VE IMPLEMENTED
differentiator for me. You're reducing attrition, you're improving the A VIRTUAL TWIN EXPERIENCE.
quality of learning for new workers or new engineers or even existing HOW DO I KNOW IT’S WORKING?
workers.”
17
INTRODUCTION
To get more information about cloud-based Virtual Twin Experience
for manufacturing or to evaluate an outcome-based model of the
ADVANTAGES OF DIGITAL
Virtual Twin Experience, please contact us
TWIN FOR MANUFACTURERS
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Unlimited Iterations
Better Insight
Improved Human Factors
Added Flexibility
Global Connectivity
Sensor Integration
Knowledge Retention
IS MY BUSINESS RIGHT
FOR A VIRTUAL TWIN
EXPERIENCE?
Our 3DEXPERIENCE® platform powers our brand applications, serving
11 industries, and provides a rich portfolio of industry solution experiences. A VIRTUAL TWIN EXPERIENCE
Dassault Systèmes, the 3DEXPERIENCE® Company, provides business and people with virtual universes to imagine WILL BOOST MYBUSINESS;
sustainable innovations. Its world-leading solutions transform the way products are designed, produced, and supported. CAN YOU CREATE IT FOR ME?
Dassault Systèmes’ collaborative solutions foster social innovation, expanding possibilities for the virtual world to improve
the real world. The group brings value to over 250,000 customers of all sizes in all industries in more than 140 countries.
For more information, visit www.3ds.com. I’VE IMPLEMENTED
A VIRTUAL TWIN EXPERIENCE.
HOW DO I KNOW IT’S WORKING?