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DIGITAL TWINS: ADDING

INTELLIGENCE TO THE REAL WORLD

#GetTheFutureYouWant
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Introduction
In Chattanooga, in the US state of Tennessee, right frequency and fidelity, thereby improving
information from 500 different sources, including performance and sustainability. It establishes a
traffic cameras, 911 emergency-call data, radar closed-loop approach to unlock value, bringing
detectors, and weather stations, feeds into the synergies across data, technologies, and business
city’s digital twin.
processes, and is at the core of Intelligent Industry3
Upon conducting experiments in traffic-congestion transformation. Through its ability to answer
relief using the twin, the city has shown an questions such as “what is best?”, “what if…?”, and
improvement of up to 30% in traffic flow, resulting “what next?”, a digital twin can not only provide
in greater energy efficiency as well as reduced visibility on how dynamic, real-world systems are
passenger delays.1 In another example, Nanyang currently performing and propose how to improve
Technological University (NTU) in Singapore, using them, but also predict how they will perform in
digital twins, was able to create 31% savings in different scenarios. A product or a system can have
energy use and a reduction of 9.6 kilotons in carbon one or more than one digital twin depending on the
emissions.2 These examples not only illustrate the stage of the lifecycle that requires it.
scale of today’s digital twins and the efficiencies
they bring but also highlight the sustainability There are various ways in which digital twins
benefits they can provide. can help organizations attain their sustainability
goals and facilitate easier collaboration with the
A digital twin is a virtual replica of a physical extended ecosystem. During the conception phase,
system that can model, simulate, monitor, analyze, a digital twin for design can aid the design effort
and constantly optimize the physical world. It and testing of new features as well as bring greater
aims to bridge the “physical-digital” gap at the efficiency to production processes, consequently

Capgemini Research Institute 2022


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Introduction
saving costs and reducing time to market. During products, energy & utilities, discrete manufacturing,
the build phase, a twin can aid virtual training and and infrastructure owners/operators. To get a first-
commissioning. Later, when the product/asset/ hand account of the value derived from and the
system is being operated and maintained, another challenges faced during digital twin implementation,
twin can make processes more efficient by reducing we focused largely on organizations with an ongoing
downtime through predictive maintenance and digital twin program (which form 80% of our
improved performance via optimization. In addition, sample), while the rest are planning to start one. We
they also aid organizations in introducing new also conducted in-depth interviews with industry
business or operating models. executives and academics.

As a result, organizations are increasingly investing


in digital twin solutions. The market size for digital
twins, which exceeded $5 billion in 2020, is expected
to grow at over 35% CAGR between 2021 and 2027.4

To understand how leading companies are


integrating digital twin technology into their
digital transformation programs, we surveyed over
1,000 organizations, spread around the world and
across industries, including: life sciences, consumer

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Introduction
This report, which is part of our series on Intelligent
Industry,5 aims to answer the following questions:

01 02 03 04 05
Are organizations How can digital How can digital Which are the How can
adequately prepared twins drive higher twins add value organizations that organizations
to deal with performance and throughout the have successfully accelerate their
changing trends? sustainability? value chain? deployed digital twin
digital twins? journey?

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Changing customer preferences, growing regulatory Our research reveals that digital twin deployments
pressures, and increased concerns around carbon are being driven by both top and bottom lines, as
emissions are compelling organizations to well as safety, sustainability, and brand reputation.
accelerate digital innovation. At the same time, Organizations working on digital twins have already
the growing convergence of products, software, seen, on average, a 15% improvement in metrics
and services is creating an opportunity for the next such as sales, turnaround time, and operational
Executive
Summary
big transformation across industries. We call this efficiency, as well as an improvement upwards of
new era of transformation “Intelligent Industry.” 25% in system performance. Further, digital twins
While technologies such as AI, cloud, 5G, and edge will provide digital and flexible ways of working to
computing are key catalysts of this journey, digital mitigate risks and extend collaboration, allowing
twins are at the core of the transformation. A digital operations to be virtual before they become
twin can optimize the design and operate and serve physical, and enabling a closed-loop feedback.
phases of any system – be it a product, its related As a result, organizations are set to increase the
services, a production line, infrastructure, a logistic deployment of digital twins by 36% on average
network, or even a system of systems. It enables over the next five years. Digital twins also provide a
collaboration all along the system’s life cycle and unique opportunity to reconcile profitable growth
across ecosystems, thereby optimizing operations and sustainability. Organizations have realized
and even helping organizations reinvent their an average improvement of 16% in sustainability
business models. How are organizations harnessing owing to the use of digital twins. However, the
this technology, and to what end? What challenges path to successful digital twin deployment is still
do they face and how can they overcome them? not without hurdles; nearly half of organizations
lack a clear vision, managerial commitment, and the
necessary investment, as well as the right skillset
within their workforces.

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We also found that 13% of organizations Foremost among these is a stepwise long-term
surveyed excel in six areas that allow them to be road map that integrates safety and sustainability
the frontrunners in digital twin deployments: goals. Additionally, in order to deploy digital twins
vision, leadership, ecosystem empowerment, at scale and obtain full benefits from the system, a
system capabilities and intelligent system set of capabilities will be required to design, build,
development, digital practices, and collaborative and operate digital twins, from system engineering
Executive

platforms deployment. Compared to the rest, and distributed architecture through simulation
Summary
these organizations realize at least 65% higher to machine learning. A digital twin architecture
benefits in the form of increased sales, improved that provides for end-to-end integration in terms
customer satisfaction, reduced costs, and of connectivity, data models, distribution, and
improved sustainability. access is key to scaling up. However, since a digital
twin is connected to a number of systems and
With digital twins still being an emerging consequently opens access to inordinate amounts
technology, it requires a value- and integration- of sensitive information, organizations must
driven stepwise transformation. To move forward also ensure reinforced data security and privacy
progressively in this transformation, companies measures prior to at-scale deployment. The greatest
need to organize themselves to support digital twins value of a digital twin comes from being able to
in terms of capabilities, road map, and governance, predict or simulate the impact of a particular change
while anticipating end-to-end integration. Based on the entire ecosystem. Therefore, on-boarding
on these elements, we highlight five key areas critical partners to the digital twin vision and
organizations need to work on to implement deploying collaboration platforms with these
successful digital twin deployments. partners will greatly augment the benefits such a
project can offer.

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A digital twin is a virtual


replica of a physical system
that can model, simulate,
monitor, analyze, and
constantly optimize the
physical world.

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01
Servitization (a shift from products to service-based optimizing total cost of ownership of assets is an
business models), sustainability, and regulatory important factor impacting them; however, only 48%
compliance impact almost all organizations today, claimed to be well equipped to do so themselves.
either directly or indirectly.
Among the industries surveyed, the energy & utilities
At the same time, organizations also need to continuously
Organizations feel ill equipped optimize total cost of ownership, time to market, and
industry is struggling most to adapt to servitization
and mass customization, with only 27% and 22% of
customer experience. However, our research shows
to face major industry trends that fewer than half of organizations feel they are
respondents in this industry suggesting they are prepared
to handle these trends, respectively.
able to meet these market demands. As many as 66%
of organizations surveyed, for example, agreed that Fig.1
Less than half believe they are equipped to tackle the major
trends impacting them

66%
Total cost of asset ownership
48%

Sustainability 62%
52%

59%
Focus on reducing time to market
52%

Regulations and compliance 58%


59%

Mass customization and personalization 57% This trend has a high impact in my industry
(of products /services) 49% My organization is well equipped to
handle the trend
Servitization (shift from product to 55%
service-based business model) 45%

Source: Capgemini Research Institute, Digital Twins survey, September–October 2021, N=1,000 organizations.

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Regarding the areas of sustainability and


total-cost-of-ownership (TCO) optimization,
the life sciences industry is lagging, with
only 26% and 28% of life sciences companies
being confident of their maturity in these
respective trends.

The consumer products industry is most


heavily impacted by almost all of these
market factors (with the exception of
servitization and regulations and compliance)
but is still lacking maturity, with just 36% of
respondents saying they are well-equipped
to handle them.

We also found that organizations are


planning to dive deeper into the servitization
trend in the next three years. Organizations
estimate that the approximate share
of revenue derived from service-based
businesses is going to rise from the current
41% to 53% in this period. In a related
projected trend, our research finds that
Several people 29% of systems within organizations today
may have coined are smart and connected, with an expected
the same new term increase in this trend to 35% within
from these roots three years.
independently.

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02
Our research shows that organizations are looking opportunity to assess the impact of each decision without
to digital twins as a way to address the various any real-world risks, thereby positively impacting key
challenges with which they are dealing. business metrics. This ensures effective decision-making
and deployment of strategies that maximize profitability,
A digital twin is a real catalyst for profitability and
maintain reliability, and improve sustainability.
sustainability. It can function as a tool that allows
experimentation with different scenarios and the
How digital twins drive higher Fig.2

performance and sustainability Digital twin investments are driven by top and bottom lines as
well as safety, sustainability, and brand reputation

Extent to which organizations agree that the below are the key drivers of their digital twin investments

Reducing time to market 73%


Top-line Introducing new business models 67%
drivers
Customer-centricity 65%
Increasing sales 61%

Saving costs 79%


Bottom-line Improving operational efficiency 71%
drivers Simplifying workflows and process 62%
complexities for employees

Technological advancement 77%


Increasing employee safety 64%
Others Improving sustainability efforts 60%
Improving reputation among 56%
employees and prospective employees

Source: Capgemini Research Institute, Digital Twins survey, September–October 2021, N=1,000 organizations.

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Digital twins positively affect working in infrastructure Digital twins can also greatly reduce “We measure any new digital twin
both top and bottom lines management and renewable time to market, which is the third- implementations against two basic
energy, is developing a digital twin most cited driver of adoption, at KPIs. The first is whether it helps
Digital twins allow organizations to the customer, such as through
to improve water treatment in one 73%. With the use of digital twins,
improve on a number of metrics, improved quality, which reduces the
its Middle Eastern desalination processes required to assemble
such as costs, operational efficiency, rate of rejection. And the second
plants. The digital twin will enable cable harnesses for the Airbus A330
turn-around times, and sustainability. is whether it brings operational
testing of operational data in the could be carried out in one-fifth
Our research shows that excellence, which includes reducing
process control system before of the time previously required.8
organizations have realized a 13% unplanned downtime. These two
implementation. This makes the This was achieved because the
decrease in costs, on average, across focus areas help in our return on
process validation simpler and allows digital twin could provide the
the various use cases of digital twins capital employed.”
optimization of system operations.7 seed for automatically generating
and a 15% increase in operational
manufacturing instructions so that,
efficiency (see Figure 3). Fig.3
Clarifying the importance of digital through tablets and augmented
twins, Surjya Kanta Pal, Professor of reality (AR) glasses, operators were Organizations realize a multitude of benefits from their digital
Cost reduction, followed closely
Mechanical Engineering and Head able to assemble products following twin implementations
by technological advancement,
of the Advanced Manufacturing the instructions on the devices.
are the top drivers of digital twin
Technology CoE at IIT Kharagpur, Digital twins also allow virtual
investments – with 79% and 77% of Average benefits realized from various digital twin implementations
says: “A digital twin gives you complete, testing, checking for errors before
organizations, respectively, citing
real-time visibility of your system. manufacturing, and improving 16%
them as such. For the construction Improved sustainability
It affords greater reliability of your designs and services – further
of Italian sports-car manufacturer 15%
systems and equipment, as it can reducing development time.9 Increase in operational efficiency
Maserati’s Ghibli model, the
identify faults and predict availability Customer engagement and satisfaction 15%
car’s digital twin helped provide
and remaining useful life. This, in turn, Another important driver for digital
developers with information for Increase in sales 15%
allows you to increase your system’s twin implementations is increased
continuous optimization, which, Decrease in turn-around time 14%
performance and reduce downtime, operational efficiency. An executive
in turn, helped them reduce both
resulting in increased production rates from an industrial aluminum Decrease in costs 13%
the costs and the time required for
and reduced costs.” manufacturing organization, echoes
development by an impressive 30%.6
this sentiment:
Acciona, a Spanish conglomerate
Source: Capgemini Research Institute, Digital Twins survey, September–October 2021,
N=800 organizations with ongoing digital twin programs, benefits averaged across the
various use cases.

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“A digital twin gives you complete,


real-time visibility of your system.
It affords greater reliability of your
systems and equipment, as it can
identify faults and predict availability Surjya Kanta Pal

and remaining useful life.”


Professor of Mechanical Engineering
and Head of the Advanced Manufacturing
Technology CoE at IIT Kharagpur.

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Digital twins enable new to be the “world’s first operational


business models and environmental industrial work
surface for deep-sea polymetallic
As seen in Figure 2, introducing
nodule collection.”12
new business models is another
major driver of digital twin
Digital twins also allow
investments. In an instance of a
organizations to reshape their
cross-industry relationship driving
business models. Through advanced
new business models through
digital twins, organizations can
digital twins, Canadian mining
employ “platform-as-a-service”
start-up The Metals Company
(PaaS) models, which allow them to
(TMC), in collaboration with Swiss
deliver value to customers in new
construction engineering company
ways. For instance, Germany-based
Allseas, is developing a deep-
compressed-air specialist, Kaeser
sea nodule-collection system to
Kompressoren, is using a simulation-
responsibly recover polymetallic
based digital twin system to
nodules10 from the sea floor and
enable the company to digitalize
transfer them to an onshore
its sales process.13 To increase
processing plant.11 In advance of
the efficiency of its “configure,
testing this initiative, TMC and
price, and quote” system, Kaeser
Norway-based Kongsberg Digital
has introduced “simulation-as-a-
are jointly creating a digital twin
service” (SimaaS) for the technical
to enable 3D visualization of
verification of customers’ proposed
deep-sea operations in a dynamic
configurations. While the customer
dashboard for review by various
benefits from a convenient view
stakeholders. While polymetallic
of their product configuration
nodules sit on the seafloor in
and greater surety of purchase
complete darkness at depths of up
experience, Kaeser derives lower
to 4 km, the digital twin will allow
cost of sales from its digital
TMC to collect polymetallic nodules
twin implementation.
in clear sight under laboratory
conditions. The project is expected

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How digital twins bridge Fig.4


Digital twins connect the physical and virtual worlds
physical and virtual worlds
According to Kari Tammi, Associate Professor Digital twins offer a platform for the physical Connect real and Create and manage Digitize end-to-end
at the School of Engineering at Aalto world to intersect with the digital. The virtual worlds virtual world core processes
University, “Digital twins can be the missing following three key channels enable this
business use case for intelligent and connected bridging of the physical and the virtual:
systems. They can harness the power of data
collected from the connected systems to tune Digital Inside is vertical integration
Digital inside Digital convergence Digital continuity
capacity, optimize production, or make products through technologies harnessing
more efficient in the real world.” the full power of distributed Connectivity services Data services Product/asset life cycle
architecture and intelligence: software, From LORA… to 5G From modeling to simulation services
… to AI/ML From design… to in-service
As a virtual replica of a physical system, a connectivity, and security.
digital twin is a reliable tool for bridging the
“physical-digital gap,” allowing risk-free, Digital Continuity is the horizontal Product/ Logistic
Embedded Distributed
low-cost system improvement. integration of processes that use architecture Asset twin: twin:
software Integrated Integrated
the power of ever maturing cloud- IoT gateway and supply chain operations
• Geometrics • Flows
A digital twin offers a single place for enabled platforms supporting intelligence
• Physics • Stocks
collaboration. Moreover, the modifiable end-to-end processes such as product/
virtual replica of a physical system allows asset lifecycle management, supply
continual monitoring and optimization along chain management, and asset or
the system’s lifecycle and across ecosystems. after-sales management. …to model, simulate, replicate and constantly optimize the physical world
In this context, a ‘system’ could refer to a
product and its related service, a production Digital Convergence is the
line, an infrastructure, a logistic network, and integration of system modeling,
Source: Capgemini.
beyond that, a system of systems. simulation, monitoring, and analysis
into ever-more powerful systems.

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Fig.5
Extended ecosystem and technological convergence together
drive intelligent industry
Open ecosystems and Meanwhile, digital convergence
combination innovation14 will will enable the development of
allow organizations to take new and sustainable business Technological Extended Paradigm shift
full advantage of distributed and operating models, such as convergence ecosystem Business
architecture and intelligence to end-to-end mobility, integrated
drive servitization strategies. supply chain, and circular Sustainability
They will also help extend economies. This is made possible
hardware lifespans and facilitate by empowering cross-industry Distributed Open and From product to services
Digital
edge computing (in which and open ecosystems around a architecture combination
inside Increased lifespan & edge
and intelligence innovation
data is processed as close to system, while optimizing existing computing
the source as possible) for capabilities all along the
improved sustainability. value chain. Digital Digital and
Extended
Integrated operating models
collaborative
continuity supply chain Increased resources productivity
platforms
Digital continuity will make
extended supply chains a reality
and optimize operating models System and Cross-industry New operating and business models
Digital system of systems and open
through seamless intra- and inter- convergence Virtual before physical…
digital twins ecosystems
company collaboration, while and loop back
increasing resource productivity.
It will also allow recycling of
scarce resources and sharing of
Source: Capgemini.
operational resources such as
transport, as well as optimization
of load rates.

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Digital twins augment employee experience by this benefit: “Design and engineering are very mature areas
improving safety, allowing collaborative ways of in terms of digital twin implementations, and the pandemic
working, and supplementing training actually expedited that a lot. While designers couldn’t
physically meet each other, they could sit in their own homes
Nearly four-fifths of the organizations surveyed
with Oculus glasses [virtual reality headsets] on and go into a
mentioned that risk mitigation is a key factor that digital
digital space with other executives and inspect the entire car.
twin technology influences (see Figure 6). Digital twins
It does eliminate the need to travel and to get people
allow organizations to reduce health and safety risks for
in a single room to be able to work on design and
Fig.6 employees in addition to reducing supply-chain risks.
engineering aspects.”
Digital twins provide a digital and flexible way of working Digital twins can increase employee safety by supporting
Royal Dutch Shell is constructing a digital twin of its
remote operations and removing the need for direct
Pulau Bukom manufacturing site in Singapore. Upon
human involvement in physically dangerous work
Which of the following ways of working planned completion in 2024, the organization is
situations. Sixty-four percent of surveyed organizations
does a digital twin impact? expecting approximately 25% improvements in levels
cite increasing employee safety as a driver of their digital
of productivity, reliability, and safety. Shell has dubbed
Risk mitigation twin investments. Through its digital twin Echo, Equinor,
77% this project a means by which “to transform the ways to
an international energy company, has been able to
work.” XR – including AR, virtual reality (VR), and mixed
achieve a reduction of up to 50% of offshore man hours
Remote before on site 71% reality (MR) – along with connected tablets, will allow
at its Johan Sverdrup oil field, cutting down significantly
real-time collaboration. Narayanan Valayaputtur, Projects
Collaboration and
on employee exposure to risks.15 According to an
and Engineering Manager, comments: “Shell Bukom’s
decision making 69% executive working with a multinational energy firm, “The
digitalization plans, anchored by the digital twin, constitute
energy industry is one of the most advanced in the adoption
In situ/in the field but augmented a shake-up of the plant. With the setting up of a virtual plant
55% of digital twins, because it can be unsafe. If you have a
(mobile, mixed reality) through the digital twin, and by equipping staff on site with
platform where you have people and there is a strong physical
tablets, we are creating a new culture of remote work, with
risk of accidents, the processes on that platform are the first
Virtual before physical 52% the provision of complex data at employees’ fingertips. This
that you want to automate. Not just that, you also want to
is an exciting time, as we are not just building digital assets,
control the risk variable. For us, that is one of the strongest
but also a new digital culture. We are telling our staff to
implementations of digital twins.”
pursue their interests in becoming data scientists or software
Source: Capgemini Research Institute, Digital Twins survey, September–October 2021,
N=1,000 organizations.
engineers, all while working in a manufacturing plant with
Digital twins also allow teams to work in a flexible
our playground of data.”16
manner, enabling remote access and collaboration. Shawn
Sehy, General Manager at Nissan Motor Corp., speaks to

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The digital twin system has


brought the concept of efficiency
by design much closer to
becoming a reality.

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Digital twin-enabled XR proves to be useful


for another key area – that of industrial
training. Equipped with accurate, detailed, Organizations are targeting a further
and true-to-life data from digital twins, XR
tools can precisely replicate scenarios workers increase of 25%+ in system performance
may find themselves in, and help them “learn
by doing” in a safe environment. Honeywell’s Driven equally by efficiency by design, and Fig.7
Immersive Field Simulator, a VR and mixed increased effectiveness of operations and
services, organizations hope to improve Organizations hope to improve overall performance by 25%, equally
reality-based training tool that incorporates
driven by efficiency by design and operational effectiveness
a digital twin of the physical plant, uses this performance of their systems by a further
concept to provide targeted, on-demand, 25% or more, taking the overall improvement
to more than 30%. Improvement in system performance
skill-based training for workers.17

The digital twin system has brought the 7.1% 27% 7.0% 26%
concept of efficiency by design much closer
26.6% 27.1%
to becoming a reality. Digital twin technology
essentially allows operational efficiency to
be fully tested at the digital design stage,
reducing the need to review and rework a
prototype, saving time and financial costs. Efficiency by design Effectiveness
Generating a virtual simulation of new in operations/service
products and systems before creating physical
versions creates the possibility of “getting it Achieved so far
right first time.” According to our research, Expected additional increase in 3 years
67% of organizations believe simulation is Delta
an impactful data service offered by a digital
twin, justifying its use.
“Delta” represents the differential in what has been “achieved so far” and the overall
increase expected in next 3 years. Source: Capgemini Research Institute,
Digital Twins survey, September–October 2021, N=1,000 organizations.

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Digital twins are enabling a collaboration, they provide a


sustainable future unique opportunity to increase
profitability, while limiting the
Digital twins can help
use of resources along the value
organizations understand and
Fig.8 quantify the impact of decisions
chain. This is made possible
Towards the effort through digital twins’ ability to
to improve system Organizations are planning to invest nearly $200 already taken, as well as compare
be virtual before physical, allow
million on average over three years various scenarios that can
performance, remote before in-situ, be in situ
on average help forecast the outcome of
but augmented, and provide a
organizations plan different decisions. As such,
Average investment ($ million) over three years to closed feedback loop.
to invest nearly $200 they can help reduce waste,
improve system performance, by company size
million over the next increase efficiencies, propose
Some use cases of digital twins
three years. The interventions, and possibly
1–5 137 that can be implemented in
size of investment automate change – helping
Revenue range of organizations ($billion)

different industries to secure


planned is directly organizations and societies
a more sustainable future –
5–10 173 become more sustainable as they
proportional to environmentally, socially, and
the size of the become more digital.
economically – are shown in
organization, with 10–20 207
figure 9.
organizations with Moreover, profitable growth
enterprise-level 20–30 263 and sustainability have, to date,
revenue greater than mostly been governed by distinct
More than agendas that are more parallel
$50 billion setting 315
50 billion than convergent. However, since
aside more than $300
million on average for digital twins are powered by
Average 196
these investments. intangible assets like data and

Source: Capgemini Research Institute, Digital Twins survey, September–October 2021,


N=1,000 organizations.

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Digital twins provide a unique


opportunity to reconcile profitable
growth and sustainability.

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01
Energy & utilities
02Automotive
03 Aviation
04
Manufacturing
Digital twins Digital twins can aid Utilizing data from an Digital twins provide Fig.9
reduce the need the design and testing electric propulsion models of “the
for personnel to process and reduce system, digital twins best way” to run a Digital twins help advance sustainability initiatives
be present at risky waste by enabling used in the design process in a given across industries
onshore fields by modeling and ensuring phases of new aircraft environment, resulting
enabling remote physical versions are can optimize in-service in reduced

05 06 07 08
operations, thereby right the first time performance and product waste
improving lifetime robustness
employee safety

Smart cities Buildings Healthcare The Earth


Among various uses, By integrating Digital twins support Work is under way
digital twins can real-time data and more extensive to create a digital
reduce emissions information received research and quicker twin of the Earth to
by managing traffic, from sensors, digital therapy development help combat climate
make cities safer by twins can identify by accurately change by simulating
identifying disease areas where energy is simulating the the atmosphere,
hotspots, and monitor being wasted human body oceans, and
Digital twins are enabling energy efficiency human systems
a sustainable future
Digital twins help advance both environmental
sustainability (through efficiency by design and Source: Capgemini
operational efficiency) and social sustainability
(through drug development, personalized medicine).

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Fig.10
More than half of the surveyed organizations lean on digital twins to
improve their sustainability, and a few are already reaping the benefits
Benefits range from process efficiencies
cutting down on emissions and waste, to
the ability to test the viability of new,
sustainable materials
Organizations are largely convinced of the
advantages digital twins can provide to
advance their sustainability efforts; 51% of
57% 51%
digital twin implementers surveyed agree
that digital twins will help in achieving their
organization’s environmental sustainability
goals. Moreover, 57% say that improving
sustainability efforts is one of the key drivers agree that one of the key drivers agree that digital twins will
of their digital twin investments. of their digital twin investments is help in achieving their organization’s
improving sustainability efforts environmental sustainability goals
Many organizations are already invested
in their quest to use this technology to
advance their sustainability agendas, with
34% having implemented digital twins at

+57 % scale to understand and predict their energy


consumption and emissions. The consumer
products and energy & utilities industries are
leading in implementations for this use case,
34% 16%
Agree that one of the key drivers of
their digital twin investments is with 52% and 50% of surveyed organizations
improving sustainability efforts in these industries, respectively, utilizing
digital twins for sustainability.

Even at these initial stages, organizations have have implemented digital twins, at scale, is the average improvement in
begun seeing an average improvement of 16% to understand and predict energy sustainability realized owing to digital twins
in their sustainability metrics through digital consumption and emissions
twin implementations across various use
Source: Capgemini Research Institute, Digital Twins survey, September–October 2021, N=800 organizations
with ongoing digital twin programs.

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cases. With increased uptake of more complex Infrastructure: Digital twins can be used a digital twin and found that cutting emissions
digital twins, this percentage is expected to to help owners of commercial buildings by 70% by 2035 would be a perfectly
increase. dramatically reduce carbon emissions. They feasible target.20
can also significantly improve efficiencies and
A number of organizations are already lower operating costs as seen in the NTU’s Energy & utilities: The development of
benefitting from the sustainable edge that example. The predictive nature of the digital five digital twins of platforms operated by
digital twins provide. twin can also be used to test the suitability Neptune Energy, an international oil and gas
of new materials. Construction company exploration and production company with
Urban planning: Singapore’s digital twin, Lendlease recently built a digital twin to a regional focus on the North Sea, North
called Virtual Singapore, is being used to test and determine the viability of building a Africa and Asia Pacific, is expected to enable
identify where best to build solar panels by multistorey complex in Melbourne, Australia engineers and integrity specialists to carry
assessing light and temperature variation from sustainable timber.19 While this timber out an estimated 4,100 hours of work from
across the country. “In this way, modelling and had been used previously in construction, it onshore locations, improving efficiency and
simulation help us optimize the amount of clean had not been tested in high-rise buildings (in cutting carbon emissions associated with
energy we can harness from the sun, in land- this case, a 29-story apartment tower). offshore travel. Additionally, digital twins of
scarce and heavily built-up Singapore,” explains two new platforms have also recently been
Tan Kok Yam, Deputy Secretary (Smart Siemens, in one of its projects with a German developed, which will support planning of
Nation and Digital Government) of the Prime city of about 200,000 residents, modeled the Neptune’s major carbon capture and storage
Minister’s Office.18 city’s energy demand and infrastructure using (CCS) project in an area capable of storing

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more than 50% of the carbon dioxide effort to shorten development times for
volumes being targeted by the Dutch vaccines, allowing them to reach people
industrial sector.21 faster and with optimum quality.24

Aviation: Rolls-Royce’s digital twin-enabled In the life sciences sector, digital twins
platform has helped it extend the time are being applied in medical-device
between maintenance for some aircraft manufacturing as well as in drug
engines by up to 50%, thereby enabling it development and personalized medicine.
to reduce dramatically its inventory of parts Gerd Hoefner, Senior Vice President at
and spares. Perhaps more importantly, it Siemens Healthineers, comments: “[Digital
Fig.11 has also greatly improved the efficiency of twins] can be used not only for diagnosis but
its engines through this platform. “Since also for testing the safety of treatments. For
Consumer products, energy & utilities, and the life sciences industries 2014, we’ve helped one of our airlines avoid 85 example, we could assess the effectiveness of
lead implementation of digital twins to understand and predict energy
consumption and emissions million kilograms of fuel and over 200 million certain cardiac drugs on a digital twin’s heart.
kilograms of carbon dioxide,” says Stuart Digital twins can also be used to digitally
Hughes, Chief Information and Digital Officer simulate cardiac catheter interventions and
Proportion of organizations using digital at Rolls-Royce.22 heart surgery in advance, to determine if there’s
twins to predict emissions, by sector a realistic chance of success.” 25
Automotive: In Capgemini Research
Consumer products 52% Institute’s discussion with Renault CIO Another effort, named the Living Heart
Energy & utilities
Frédéric Vincent,23 he revealed how the Project, is attempting to develop and validate
50%
car-crash safety test, which was earlier highly accurate personalized digital models
Life sciences 42% conducted “by throwing the car into a wall… of the human heart, which will establish a
multiple times,” could become more efficient unified foundation for cardiovascular in silico
Discrete manufacturing 32% through the use of a digital twin of the car in medicine and serve as a common technology
Infrastructure owners/ the cloud to simulate the crash and update, base for education and training, medical
operators 22%
upgrade, and change required parameters. device design, testing, clinical diagnosis, and
Global 34% regulatory science – creating an effective
Healthcare: With reference to the social path for rapidly translating current and
aspect of sustainability, GSK and Siemens future cutting-edge innovations directly into
Source: Capgemini Research Institute, Digital Twins survey, September–October 2021, are collaborating to digitalize the vaccine improved patient care.26
N=800 organizations with ongoing digital twin programs. development and production process in an

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Consumer products: Kim Kirkconnell, Vice


President, IT Global Digital Supply Chain,
Kimberly-Clark, speaking to their sustainability Organizations will significantly increase
efforts, commented: “We are using technology
and innovation in various areas. For instance, in digital twins‘ deployment
North America, the Huggies brand introduced
diapers made with plant-based ingredients. We Digital twin implementations are set to increase
are already using sensor analytics to track our by 36% on average over the next five years Fig.12
energy and water consumption to monitor our Organizations aspire to increase digital twin Organizations already working on digital twins are set to increase
footprint. In the future, we will be looking at deployments in the near future. Of every 100 their deployments
opportunities to apply digital twin technology in physical ”systems” within an organization with
making our products more sustainable.” 27 digital twin implementations, on average 42 are 44%
already using a digital twin. In the next five years, Logistics
In another example, Unilever is making use 59%
this number is projected to increase to 57, a growth
of digital twins at a facility in Brazil to make of approximately 36%. Since our survey uses a
production more efficient. The company Industrial systems/ 43%
targeted sample of organizations already having a production lines 56%
used a digital twin to set manufacturing digital twin program, the base numbers are higher
parameters; for example, the temperature than the absolute market adoption numbers.
at which soap is pushed out before being cut Assets/ 42%
infrastructures 57%
into bars. The project resulted in a saving of The deployment of digital twins is fairly balanced
$2.8 million by reducing energy usage and between greenfield, brownfield, and a mixture of
improving productivity by 1–3%.28 Products and 39%
the two, with about 30% of organizations marking related services 55%
each as their preferred method. The energy &
utilities industry has the highest percentage of
brownfield deployments across all industries, with
Deployed so far
40% of implementers within the sector classifying
To be deployed over the next 5 years
their digital twin deployments as brownfield, and
33% adopting a mix of greenfield and brownfield.
Source: Capgemini Research Institute, Digital Twins survey, September–Octo-
ber 2021, N=800 organizations with ongoing digital twin programs.

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“In the future, we will be looking at


opportunities to apply digital twin
technology in making our products
more sustainable.”
Kim Kirkconnell
Vice President, IT Global Digital Supply
Chain, Kimberly-Clark

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03
A digital twin, in its simplest form, is a virtual twin of a Product twin that allows faster time to market and
single component or a single unit of equipment, such as a improved system operations
robotic arm. This is a unit-level digital twin. By architecting
and connecting such simpler twins, a system-level New product: during the design and development of
digital twin can be constructed. This will augment the new products, digital twins can be used to improve
efficiency gains realized from the individual twins. For product design and reduce time to market and can also

Digital twins add value example, a digital twin of a production line, a system-
level twin, can be created by connecting digital twins
maintain engineering-manufacturing continuity.

throughout the value chain of multiple machines. Extending this further, a digital
twin of a factory or even of a network can be created by
Industrial system: digital twins of industrial
systems allow integration of products, processes and
connecting multiple production lines/factories together resources, thereby improving the system output and
(a system-of-systems digital twin). providing scalability.

When we look at what the digital twin is being used to The automotive industry has been using digital twins, not
simulate, broadly, it can be categorized as a product, necessarily under that name, in their design (such as the
asset, or network twin. In fact, a product or a system design of assembly lines) and engineering departments
can have multiple digital twins – for instance, one twin for more than a decade. Over the years, the applicability
covering the design, one twin covering the production, of digital twins has expanded and, today, digital twins
and one for the maintenance part. Depending on whether can help automotive manufacturers achieve end-to-end
we are looking at the twin of a product or an asset or a digital continuity and thereby provide additional value
logistics network, there are a variety of ways in which to customers. Tesla, for example, relies on digital twins
value is derived or added. A digital twin can, based on use to improve its customer experience. It creates a digital
case, be broadly classified into the following categories: twin of every car it sells; data from the sensors is fed into
each car’s simulation and, using AI, Tesla can determine
whether the car requires maintenance or if it is working
as intended. Further, Tesla can even update the car’s
software through over-the-air updates.29

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Extending the previous use case power we are going to provide to


of Tesla further, digital twins the grid, and at what frequency,
can even be used to optimize and our [back-up] plan if we are
the design of future products unable to do so. Through the use
Fig.13
through generative design. of digital twins, we now have
Issues solved and value added by a product digital twin Based on the data obtained a more predictable generation
from the products already in the schedule, with very minimal
Value added by Digital-twin field, digital twins, coupled with potential deviation or variance,
Key characteristics Issues
digital twin backbone generative design, could be used thereby avoiding the stringent
iteratively to modify product regulatory and financial penalties
Feed in customer and EDA/CAD/CAM-DMU(2) design and simulate lifetime characteristic of our industry.”
in-service insights +
Lifetime: 2–20 years
PLM backbone
performance under real-world
Faster portfolio conditions.30 Figure 13 shows the key
Allow platforms and +
New products rotation
re-use In-service insights characteristics of a product twin,
Tier-1 ecosystem (smart & connected product) Talking about the predictability the business issues it can solve,
Simulate Monitor Predict
benefits, an executive and the value added.
working with the energy and
utilities business of an Indian
Enable CAD/CAM-DMU(2)
Lifetime: 10–50 years System output product-process- + conglomerate, says, “In the power
optimization resources PLM backbone industry, we essentially need to
integration(1) + submit our power-generation
Industrial system Critical industrial Flexibility, scalability, Shopfloor data schedule, in terms of how much
system and safety Simulate Monitor Predict (PLC/IOT, Jig and tools)

(1) Manufacturing continuous processes will require dedicated design and simulation tools (2) CAD/CAM:
Computer-aided design / manufacturing; DMU - Digital mockup; EDA – Electronic design automation.
Source: Capgemini analysis.

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Fig.14
Logistics twin that provides Philip Morris International (PMI)
agility and resilience through has created a digital twin of its Issues solved and value added by a logistics digital twin
simulations in addition to global manufacturing footprint.
optimization This allows the company to
assess the impact of changes Value added by Digital-twin
Key characteristics Issues
digital twin backbone
Networks: digital twins in product portfolio, market
provide simulation of regulations, and even business Quality of customer Enable market- and Network design
supply and demand disruption. The solution service at acceptable demand-driven supply +
networks, allowing allows PMI to run forward- Extended enterprise
cost chain Collaborative &
organizations to improve looking optimization scenarios Flexibility and Allow dynamic integrated planning
performance, resilience, and considering manufacturing Network +
Enable portfolio resilience network configuration
sustainability for augmented cost, import/export duty, and Control tower
rotation Sustainability Simulate Monitor Predict
customer centricity. transportation costs across
the network. The company has
Warehouse/ distribution consequently reduced the use Enable demand- and
center: digital twins allow of spreadsheet simulations by Node between event-driven ERP
effective process resource 90% and was able to decrease factories and operations +
Shorten lead time
distribution Execution Systems
integration in a warehouse or the time required for scenario Enable
+
distribution-center context. evaluation from weeks to Warehouse/ Overall effectiveness process-resource
Operated on its In-operations
hours.31 Distribution center integration
own or subcontracted insights
Monitor Predict Simulate

Source: Capgemini analysis.

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Asset twin that extends — can be simulated to support Fig.15


the lifetime of assets and a wide variety of AI-enabled use
cases, such as virtual factory Issues solved and value added by an asset twin
moderates the total cost of
ownership planning, autonomous robots,
predictive maintenance and big
Value added by Digital-twin
Existing assets/ data analytics.” This approach is Key characteristics Issues
digital twin backbone
infrastructure: digital twins expected to produce 30% more
can lower the total cost of efficient planning processes.32 Act as an asset single CAD-BIM
ownership (TCO) of existing Output optimization source of truth +
infrastructure or assets by Neara, an Australian software Twin for operators
Lifetime: 15–70 years TCO optimization Enable data-centric
providing a single source of company, enables utilities backbone
truth, as well as a data layer, companies to design, simulate, Existing assets/ collaboration +
infrastructure Extended operation High availability/
allowing teams to collaborate and manage their assets (such ecosystem Some PDM features
flexibility Monitor Predict Simulate
in a seamless manner. as power lines). Daniel Danilatos,
Founder and CEO, elaborates:
New asset generation: for “In the past, if you wanted to look CAD-BIM
new assets, digital twins will at a utility pole and understand Lifetime: 25–100 years Asset delivered with Enable digital +
reduce the time to operate how it behaves and if it needs its digital twin collaboration and PLM from design to
Design-build-operate continuity all along virtual commissioning
and also optimize the TCO. replacing, it will take a lot of effort
Time to operate the lifecycle +
to make that decision accurately. If New asset generation Different ecosystems Twin for operators,
BMW Group announced the you wanted to make that decision (e.g., nuclear power) all along the lifecycle from handover to
TCO optimization Simulate Monitor Predict
design of a digital twin of an across millions of assets [in this operations
entire factory, which it can use case, poles], you couldn’t do it
to simulate the operation of quickly. [Our software] mitigates
31 of its existing physical sites. the trade-off between the depth of Source: Capgemini analysis.
Milan Nedeljkovic, Member of understanding and the scalability
the Board of Management for [of the task].”33
BMW AG, says, “All elements of
the complete factory model —
including the associates, the robots,
the buildings and assembly parts

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Digital twin systems allow around the world – is through Fig.16


data-driven decision-making standardization of data. Digital
Digital twins allow insight to be extracted from data in real time
all along the lifecycle and twins can help consolidate
across ecosystems information and drive a common
criterion in the way you save and Most impactful data services offered by a digital twin
Digital twins allow teams to
read data. Apart from helping
collaborate on different kinds
data management, this can also
of data service. The greatest Rapid access to the right data 71%
aid in breaking silos within the
impact of digital twin technology
organization and working in a more
comes from its ability to provide
integrated manner.” Prediction 69%
rapid access to the required
data, as mentioned by 71% of
The second-top-rated use case
the organizations in our survey. Simulation 63%
The quantum and the complexity
of data is rapidly increasing
is its ability to predict, with
69% ranking this as the most digital twin
impactful service. As illustrated Loopback, analysis & improvement 60%
day by day, and digital twins A product or a system
in Figure 16, digital twins also
help designers, engineers, and can have multiple
allow simulation and provide Monitoring & event orchestration 59%
analysts make sense of this digital twins – for
inputs to be fed back into design
data in an intuitive manner instance, one twin
and development.
and gain valuable insights. An Modeling 55% covering the design,
executive from a global energy one twin covering
organization says, “An important the production,
way that digital twins help large and one for the
Source: Capgemini Research Institute, Digital Twins survey, September–October 2021,
organizations like theirs – that N=800 organizations with ongoing digital twin programs. maintenance part.
have large portfolios of assets

+69 % 65%

61%
rank “Prediction“ as the most impactful
data service offered by a digital twin

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The path to successful digital


twin deployment is not
hurdle-free

Although organizations have realized • While 59% of organizations claim to have


the benefits and applications of digital drawn up a long-term (five years or more)
twins, there are a number of challenges to roadmap to develop a digital twin system,
successful deployment. We identified the about half of organizations (43%) report a
following four major areas of challenges that lack of managerial commitment to digital
are slowing digital twin deployment. twin initiatives and 49% face the challenge
of a lack of investment in the concept.
I: Overcoming a lack of strong vision, • 56% of organizations are dealing with a
management support, and well-balanced lack of digital continuity across systems
governance and processes, and 55% report a lack of
cross-functional collaboration.
A lack of management support, coupled with
• The reported lack of strong governance
operational problems, is, in some instances,
also leads to inefficient program
causing digital twin implementation to fail.
management: at one-third of the
• Even though 55% of organizations consider
organizations surveyed, digital twin
digital twins a strategic part of their digital
governance has not been formalized or is
transformation, around half of them (42%)
completely lacking.
lack a clear vision as to how to deploy them.

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II: D
 evelopment of core business and IV: Empowerment of the ecosystem Fig.17
collaborative skills remains a significant challenge Core business skills necessary for digital twin implementation
Further, digital twin implementation Large organizations find themselves
requires a specific skillset, the lack of which dealing with hundreds or even thousands 63%
Embedded software
poses a challenge for many organizations. of suppliers. In order to work with these 55%
Figure 17, highlights the core business skills suppliers and other partners in a more
required for digital twin implementation and efficient manner, collaboration platforms 62%
Cybersecurity and blockchain 52%
maintenance. Additionally, cross-functional are essential. However, as shown in Figure 19
collaboration is another critical skill (as cited below, fewer than half have deployed such Connectivity 62%
by 58% of respondents); however, only 50% a platform for collaborative use with their 51%
confirm that they have this skillset available partners (albeit, on average, this is
within the workforce. projected to increase to 58% within the Federated data models, ontologies, 61%
next three years). knowledge management 46%
III: Deployment and integration of a
61%
secured end-to-end architecture Hybrid cloud
53%
Additionally, a number of technological 59%
challenges are hindering organizations from Hardware 53%

+61
realizing the full potential of digital twins
within their specific contexts. With digital % 59%
Data capture
twins having to “speak” to many systems, 43%
including legacy systems, API integration,
connectivity, and other measures are organizations agree that federated data
necessary to collect data. Inadequate internal models and ontologies are necessary Importance Extent of availability
for digital twin implementation
digital infrastructure is further hindering
progress in this respect; 67% of organizations
Source: Capgemini Research Institute, Digital Twins survey, September–October 2021,
say that insufficient cloud deployment and
N=800 organizations with ongoing digital twin programs.
API integration constitute a major challenge
for them.

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Fig.18 Fig.19
Technological challenges that impede the progress of Collaboration within ecosystems and deployment of collaborative
digital twin deployment34 platforms will increase by more than 35%

Hybrid cloud deployment and APIs integration services 67% To what extent have you deployed
digital-collaboration platforms with your partners?
Integration with company OT/IT
backbones and platforms (PLM, ERP/EAM, IOT,…) 57%
36%

Flexible data modeling and mapping deployment 56%


58%
Necessary and sufficient updates for digital twin 53%
43%
Right mix of computing capabilities: device, edge, cloud 53%

Inability to access or integrate 52%


data with suppliers and/or clients

Continuous connectivity requirements 51%

Deployment of ontology and semantic technologies 51%


Deployed currently After 3 years Delta
Cybersecurity and blockchain 50%

Source: Capgemini Research Institute, Digital Twins survey, September–October 2021, Source: Capgemini Research Institute, Digital Twins survey, September–October 2021,
N=800 organizations with ongoing digital twin programs. N=800 organizations with ongoing digital twin programs.

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“ {Digital twins} can be used not


only for diagnosis but also for
testing the safety of treatments.”
- Gerd Hoefner, Senior Vice President at Siemens Healthineers

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04
Fig.20
Frontrunners outperform others in all six areas of transformation

Vision and leadership


97%
Frontrunners in the digital twin
journey win the greatest benefits System
82%
70%
Intelligent
capabilities 89%
45% systems
59% 63%
Who are the frontrunners • Capabilities and practices Capabilities 46%
21%
in this digital twin – system capabilities available & practices
Technological
transformation? – digital practices – data-
37% 36% integration
driven and digital ways
While digital twins allow 39% 68%
of working – within 70%
organizations to enjoy 93%
the organization 94%
a multitude of benefits, Digital practices Collaborative
• Extended ecosystems
organizations do need to have 82% platforms
certain elements in place in order
Based on the above, three
to capitalize fully on the systemic 98%
cohorts emerged:
enhancements. We analyzed Extended ecosystem
• Frontrunners: perform well in
the organizations in six affected
all areas (13% of the surveyed Frontrunners Experimenters Novices
areas:
organizations)
• Vision and leadership • Experimenters: perform
• Technological integration well in some of these six areas Note: Scores on each axis are rated from 0 to 100%, with 100% being a perfect score.
– collaborative platforms (10%) Source: Capgemini Research Institute, Digital Twins survey, September–October 2021, N=1,000 organizations.
– intelligent systems: smart, • Novices: perform poorly in all
connected, and sustainable areas (77%)

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Frontrunners are able to realize


significantly higher benefits
In our analysis, we found that frontrunners are
Fig.21 Fig.22 in a position to realize higher benefits. Owing
to digital twins, frontrunners on average
Frontrunners realize an additional 40%+ improved system Frontrunners realize anywhere between 65% and 75% higher
performance and extended lifetime compared to others benefits compared to others report a 40% improvement in overall system
performance, compared to 27% realized by
others. One of the reasons for this is that
76%
Increase in system performance and lifetime extension frontrunners are able to utilize efficiency by
71%
through digital-twin implementation 68% design and achieve operational efficiency to a
65%
much greater degree.
49%
45% Similarly, frontrunners report a 76%
greater reduction in costs and 68% greater
40% improvement in customer engagement
37%
compared to others (see Figure 22).
27% 26%
23% 24% 23%
21%

12% 13% 14% 14%

Overall system performance Lifetime prolonged due to Decrease in Increase in Improved Improved customer
improvement achieved owing digital twins, on average, costs sales sustainability engagement and
to digital twins of all systems satisfaction

Frontrunners Others Delta Frontrunners Others Delta

Benefits are averaged across the five categories: products and related services, industrial “Delta” represents the differential in benefits attained by the frontrunners.
systems/production lines, assets/infrastructures, logistics, and after-sales support and Source: Capgemini Research Institute, Digital Twins survey, September–October 2021,
services. “Delta” represents the differential in improvement attained by the frontrunners. N=131 frontrunners, N=869 other organizations.
Source: Capgemini Research Institute, Digital Twins survey, September–October 2021,
N=131 frontrunners, N=869 other organizations.

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05
Organizations across industries are relying on digital employed by early adopters, our survey results, and our
twins to reduce time to market, improve their operational market experience, we have identified the following areas
efficiency, meet their sustainability agendas, and improve in which organizations need to invest to drive their digital
their customer experiences. However, many are yet to twin transformation at scale.
install the required infrastructure to scale digital twins
successfully and thereby enjoy the complete spectrum
Fig.23
How to accelerate transformation of benefits on offer. Drawing on the best practices
Accelerating digital twin transformation
through digital twins?
Empower the ecosystem partners
to derive greater benefits

Develop a stepwise
Enhance data long-term roadmap
security and privacy for deployment,
across networks considering
sustainability and
Scaling
safety goals
digital twins

Strengthen key enablers


required for scaling:
connectivity, data
Anticipate and enable management, capabilities,
end-to-end integration user experience, and
user interface

Source: Capgemini Research Institute analysis.

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Develop a stepwise long-term utilization, operational-efficiency


roadmap for deployment,
considering sustainability and
improvements, and cost savings
along the entire value chain.
A well-thought-out design of your
safety goals Another important point that
organizations need to consider
digital twin is critical – it is the
Organizations typically start their
digital twin journeys with a pilot or
while deciding on the business compass needle, and you want to
proof of concept. It is important,
however, to have a roadmap for
case for digital twins is that not
only do digital twins help with be going in the right direction
scaling digital twin deployment. As
existing systems, but they also
allow organizations to introduce
from the beginning. ”
many as 97% of frontrunners have
new business models and unlock
a long-term roadmap (five years or
revenue opportunities.
more) for digital twins, compared
to just 58% of others. A roadmap
Deploy use cases that will
helps the organization identify
address repetitive pain points
the gaps in each function of the
or strategic issues first
organization and the enablers
Full-scale digital twin deployment
(data management, skillsets, etc.)
requires significant investment in
required to plug those gaps. The
terms of the software, time for
roadmap also ensures that the
deployment, skilled resources,
Sacha Porges
necessary funding is channeled
and budget. So, once proof of Global Director, Customer Quality
towards these initiatives. While
concept is out of the way, it is & Programs at GKN Automotive
working with limited budgets
advisable to take up the use cases
for digital transformation
where a digital twin has already
and other on-going projects,
proven beneficial, and where its
organizations might also consider
application will address some
the safety benefits that digital
pain points or strategic issues.
twins bring, through virtual,
Elaborating on their digital twin
remote, and augmented on-site
initiatives, Amy Sausen, former
approaches (see Section 2), as
Global Director, Digital Technology
well as the sustainability benefits
at Kimberly-Clark, comments:
through optimal resource

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“The [digital twin] technology is not yet ready each digital twin and which entities are more closely connected in today’s business
to help us in product innovation, because responsible for maintaining data hygiene (i.e., environment. Connectivity and security
using fluid dynamics in a digital environment synchronization of the digital twin with the are required to ensure continuity of
(for example, trying to model how a Kleenex physical source, data quality, prevention of information from edge to cloud and from
tissue or a Huggies diaper absorbs moisture) unauthorized changes to the data, etc.). design to operations and services, all along
can become very complex. However, using a the supply chain. Only then can the full
digital twin to create an environment where a A key consideration for the governance team benefits of the system be realized.
system can be monitored in real time, learning is ensuring that the employees who would
from that, and converting those insights into be using the digital twins are aware that the Data management: In order for the
predictive or prescriptive actions is a stronger digital twins can augment their work and digital twins to model, simulate, predict
application because of the vast amount of data aid in further decision-making. This means and monitor effectively, data continuity
available within manufacturing operations. We ensuring that the immersive experience and integration with multiple data sources
are piloting the predictive maintenance use case provided to the employees is consistent with is necessary. For digital twins to mimic
for a machine currently, to understand when the their operations. Organizations can achieve operational behaviors, quick computation
machine might break down and the reason for this by providing employees with
breakdown.” 35 the required platforms and tools

Address quick wins to convince employees


to test the applications, while
simultaneously learning in a
Setting up data interoperability a
of the value addition supportive culture that encourages priori through an ontology or a
Whatever the type of digital twin, the value employees to upskill and innovate.
can be unlocked only when employees series of ontologies helps manage
interacting with the twin are able to use the
application for analysis, course correction,
Strengthen key enablers
required for scaling
the complexity of digital twins.
or prediction. Working on quick wins such as
In order to deploy digital twins
tracking the flow of assets on a shopfloor, for is critical. Further, the data from the
at scale and obtain full benefit from the
instance, will help convince the employees of various systems needs to be analyzed and
system, organizations must ensure certain
the value and also act as a lighthouse project. interpreted. This can be accomplished
foundations are in place.
in a speedy manner by setting up data
A well-defined governance structure also interoperability a priori through an
Secured connectivity: Systems,
helps establish which entity within the ontology or a series of ontologies. This
organizations, and processes are ever
business owns the data generated from can help manage the complexity of digital

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“Using a digital twin to create an


environment where a system can be
monitored in real time is a stronger
application because of the vast
amount of data available.” Amy Sausen
Former Global Director, Digital
Technology at Kimberly-Clark

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twins and make relationships explicit. Some so organizations would also need to scale User experience and user interface:
ontologies can also help in data modeling their infrastructures and scale up their Finally, an intuitive UX/UI is necessary
and address issues such as missing data cloud systems. to exploit the full potential of smart,
and data security. Frontrunners recognize connected systems and processes in the
Capabilities: Organizations will also need
these challenges, with 95% mentioning field. Employees using digital twins must
to strengthen certain skillsets in order to
that a unified data platform is essential be able to use, navigate, and immerse
design and operate digital twins.
to successful implementation of a digital themselves in the application and, in order
twin, compared to just 54% of others who to achieve this, the UX as well as the UI
Design capabilities: Skillsets such as
suggest the same. must be well-thought-out and intuitive for
systems engineering, modeling, and multi-
the users.
dimensional simulation are necessary in
As the digital twins scale, this challenge
designing the digital twin system
becomes even greater, and organizations Sacha Porges, Global Director, Customer
Operate and serve capabilities:
must determine how to develop these Quality & Programs at GKN Automotive,
These include data capture, distributed
ontologies, whether to use any current underlines the importance of these enablers:
architecture, artificial intelligence/machine
ones or to create new ones, and how these “A well-thought-out design of your digital twin
learning, as well as event-management
are going to be validated and maintained. is critical – it is the compass needle, and you
capabilities
To benefit fully from digital twins, want to be going in the right direction from
Collaborative skills: All along the value
organizations must design and deploy a the beginning. You need to know the enabling
chain, across both internal and external
data-management strategy. Digital twins technology to be able to integrate the physical
ecosystems
can also be computationally very intensive, assets with the digital twins: how you would

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Fig.24 connect the physical to the virtual, cases or quick wins, all these
and what technology would you three layers can be addressed
A high-level digital twin architecture
need to do that. Similarly, to enable separately or through model-
real-time flow of data from the based systems engineering
IoT [internet of things] devices (MBSE). MBSE also provides the
Digital twin Services layers provided by digital twin architecture and integration with operational interoperability among these
COLLABORATIVE and transactional data from other three layers that is required for
PLATFORM enterprise systems, you must define complex use cases.
the types of devices and software
Twin business services enablers
needed.” The figure also shows the service
Model-based
simulation layer Graph Life cycle management Virtual build layers that the digital twin
visualization cockpit and digital continuity Realistic simulations Design and implement a digital architecture provides. It allows
twin architecture physical-digital integration by
DATA CONTINUITY Digital collaboration and continuity
means of data collection and
A digital twin architecture helps
storage, data capture and device
deliver the digital twin initiatives
QUICK WINS control, and through embedded
Predictive models in a smooth manner. Figure 24
ENTRY software. Further, digital
POINTS Data management shows a high-level architecture
Data integration and transformation around business objectives collaboration and continuity
MBSE layer with three major technology
is enabled through data
APPROACH foundations required for
integration. In order to realize all
delivery, along with the services
Physical-digital integration these successfully, organizations
DATA CONTINUITY that a digital twin enables.
should focus on lifecycle
management, digital continuity,
Data & software “in service” twin As explained in the previous
Device and realistic simulations, and cockpit
recommendation, a data-
software layer Data collection Data capture and Embedded & dashboard services.
management layer allows for
and storage device control software
easy analysis of data. A device
The bottom layer shown in Figure
and software layer allows for
24 provides for data collection in
employees and teams to interact
order to build a single and up-to-
Source: Capgemini. with the twin. For simple use
date source of truth federating

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“cold” (historical system specifications and Ensuring only authorized access to system Collaborate with partners to derive
models etc.,) and “hot” (IOT, OT, real-time facilities and data is paramount in protecting greater benefits
events) data, as well as “descriptive” (GIS, the confidentiality of business and personal The greatest value of a digital twin comes
BIM, CAD/CAM, etc.) and “transactional” information. from being able to predict or simulate the
(PLM, ERP, MES etc.) data. The modelling impact of a particular change on the entire
of a digital twin should be flexible and In addition, unauthorized modification or network of partners. This can be made
be able to offer advanced data services, destruction of data/operations while being possible only by feeding data or inputs from/
such as modeling and simulation, intuitive processed, in transit, or in storage must also about partners into the digital twin. In order
visualization, analytics and AI/ML, and be prevented. The integrity of the system to build such complex twins, which extend

+47 % event-orchestration, to manage predictive/


preventive alerts and real-time incidents
efficiently.
must be maintained to preserve confidence
in the reliability of the data it produces and to
ensure non-repudiation and authenticity of
commands/actions. Obviously, this requires
far beyond the boundaries of the individual
organization and into the wider ecosystem,
organizations need to on-board their critical
partners to the digital twin vision and deploy
of organizations are considering strategic
partnerships for digital twins initiatives
However, a single source of truth does not secure communication between the digital collaboration platforms.
necessarily mean that all data sources and twin and its physical counterpart.
computing activities need to be centralized in Organizations also realize that they
one place; data consistency and performance An adversary affecting a digital twin or need to collaborate or partner with

+38 % would not be manageable in such a scenario. its physical counterpart can introduce technology companies to drive digital twin
Therefore, striking the right balance in divergence in the behaviors or states of the implementations. Johnson Controls, HVAC
terms of data-sizing, synchronization, and two entities. Given the bi-directional link (heating, ventilation, and air conditioning)
computing is critical to scaling up. between the two, an attacker may negatively and security equipment manufacturer
of organizations are willing to work with affect both through changes in either. for buildings, for example, announced an
new/existing partners towards digital twin
implementation
Enhance data security and privacy integration between the Azure Digital
across networks The privacy and security risks associated Twins IOT platform and its own OpenBlue
with digital twin deployment are manifold. Digital Twin platform to maximize efficiency
Since a digital twin is connected to a
Reinforced data security and privacy while managing physical spaces.36 Beyond
number of systems and consequently opens
measures are, therefore, indispensable prior suppliers and customers, organizations are
access to inordinate amounts of sensitive
to digital twin deployments – a sentiment working with a variety of partners, which may
information, hacking into an unsecured
echoed by 69% of surveyed organizations, include IT vendors or consulting and system
digital twin allows immediate access to the
who plan to effect major changes in their integrators (C&SI), software firms, startups,
internal data of the entire business system.
end-to-end cybersecurity. hyperscalers, financial institutions, original

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Fig.25 equipment manufacturers (OEMs), and telco Similarly, consortiums play a role in the
operators. Further, 47% of organizations design and development of digital twins.
C&SI partners and software firms remain the top preferred are considering strategic partnerships for They help in the adoption of standard
partners for digital twin initiatives
digital twin initiatives, while another 38% are formats and provide resources or guidelines
willing to work with new/existing partners to organizations, thereby increasing the
Preferred partners for digital twin implementations towards digital twin implementation. Among scale of adoption. For instance, Digital Twin
the various potential partners, 46% of Consortium, which counts Microsoft, GE
organizations rank IT vendors/C&SI as being Digital, and Northrop Grumman among
IT vendors/C&SI 46%
among their top-three preferences, followed its founders, is working on advancing best
by software vendors (see Figure 25). practices and standards requirements. The
Software vendors 35% members aspire to drive consistency in
The energy & utilities sector is keen to the vocabulary, architecture, security, and
Start-ups 31% harness the potential of digital twins. interoperability of digital twin technology.39
However, while they are focusing on small-
Hyperscalers 30% scale twins, building digital twins for an
electric grid or a nuclear reactor is definitely
Financial/Insurance companies 28%
complex, and it is often difficult for the
organizations to develop these advanced
twins on their own. As a result, we see
Original equipment manufacturers (OEMs) 28%
organizations collaborating with software
vendors and equipment providers. E.ON,
Third-party manufacturers 26% for example, is working alongside multiple
industry partners through a consortium to
Telco operators 22% create a digital twin that monitors asset
health and performance of its 110 kV power
transformers.37 Separately, French utilities
Source: Capgemini Research Institute, Digital Twins survey, September–October 2021, giant EDF is also planning to deploy digital
N=800 organizations with ongoing digital twin programs.
twins for its fleet of 56 nuclear reactors – in
collaboration with various academic and
industry partners.38

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Partner with Capgemini for


transformation with digital twins
We propose a set of digital twin solutions to deliver value at speed

A complete and Federated data


agnostic immersive model integrating
remote platform, natively 1D-3D,
for assistance and geographical
acceptance, providing ReflectIoD information and IoT
IMMERSIVE
REMOTE digital continuity of DIGITAL TWIN FOR
ASSET FLEET
data for augmented
COLLABORATIVE 3D models MANAGEMENT operations
PLATFORM

From secured
sensor and OPCUA
connectivity to
MANUFACTURING end-to-end OEE
PERFORMANCE management
PLATFORM

Capgemini Research Institute 2022


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Research Methodology

To understand how leading companies are


approaching digital twin transformation,
we carried out extensive research with both
qualitative and quantitative components.

In-depth interviews
We conducted 14 in-depth interviews with 13%
industry experts, academics, and think tanks Country of headquarters of organization Annual revenue of organization (in USD)
from various organizations and universities.
Australia
Executive survey United States
Canada 8%
We surveyed 1,000 organizations, 80% of 26%
10% 5% 5%
which have an ongoing digital twin program, United Kingdom 16%
France
with the rest planning to start one. The 8% 10%
distribution of selected respondents and
their organizations is provided in the Sweden 8%
following figures. 20%
10% Germany
30%
The study findings reflect the views of Spain 8%
the people who responded to our online 7%
questionnaire for this research and are 6% India
Between 1 and 5 billion
South Korea
8%
aimed at providing directional guidance. 8% 7% Between 5 and 10 billion
Please refer to the methodology for Italy Between 10 billion and 20 billion
details of respondents and get in touch The Netherlands Between 20 and 50 billion
with a Capgemini expert to understand Japan More than 50 billion
specific implications.

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Sector distribution of organization


Digital twin implementation journey
Industrial equipment
Automotive
Life sciences 19%
20% 25%
Discrete
manufacturing
40%
10%
Energy
& utilities 29%
30% 27%
41% High tech Aerospace
15% & defense

We are planning to start to implement


a digital twin within the next 12 months
We have an ongoing digital twin program 15%
focused on one specific part of the value chain
Ports
We have an ongoing comprehensive digital
twin program across the whole value chain Consumer 14% Buildings
products 30%
27%
Airports(including Air
traffic management) 20%
Infrastructure
owners/operators
22%
17% Surface
Railways transportation
(Roads)

Source: Capgemini Research Institute, Digital Twins survey, September–October 2021, N=1,000 organizations.

Research methodology *The study findings reflect the views of the people who responded to our online questionnaire for this research and are aimed at providing directional guidance.
Please refer to the methodology for details of respondents and contact a Capgemini expert to understand specific implications.

Capgemini Research Institute 2022


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References
1 SmartCitiesDIVE, “Are digital twins the 5 Other pieces in the Intelligent Industry series 7 Siemens, “Siemens in collaboration with
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3 Capgemini coined the term “‘Intelligent com/research/conversations-for-tomorrow/ 9 Ibid.
Industry”’ to describe the next era of conversations-for-tomorrow-3/. 10 Deep-sea polymetallic nodules are mineral
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fostering synergies between the digital 2021, https://www.capgemini.com/ the sea bed. They contain significant
and engineering worlds to help companies research/software-the-new-battleground- amounts of critical metals required for
build intelligent products, operations, and of-the-automotive-industry/. urban infrastructure. Deep-ocean mining
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together engineering, IT, and digital and June 2021, https://www.capgemini.com/ environmental issues associated with
thereby allows a convergence of the physical research/the-5g-industrial-revolution/. terrestrial mining and has a lower carbon
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4 Global Market Insights, Digital twin market https://www.capgemini.com/research/ articles/s43017-020-0027-0
size by application (product design & sustainability-operations/. 11 K ongsberg, “The Metals Company enters
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monitoring, process support & service), Operations, December 2019, https:// develop digital twin of deep-sea operating
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automotive, aerospace & defense, energy scaling-ai-in-manufacturing-operations/. collection system test,” November 2021.
& utility, infrastructure buildings, retail • Smart Factories @ Scale, November 2019, 12 Ibid.
& consumer goods), Industry Analysis https://www.capgemini.com/research/ 13 SAP, “How will a leading compressor
Report, Regional Outlook, Growth Potential, smart-factories-at-scale/. company reinvent sales with a digital twin?”
Competitive Market Share & Forecast, 2021 – 6 Siemens, “Getting to market quickly,” 2020.
2027,”July 2021. October 2015.

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14 Combination innovation refers to Transformation, Discussion with Renault 33 Australian Financial Review, “Big-name VCs
innovation that is made possible as a result Group,” 2021. pile into digital twin company Neara,” April
of the combination of different concepts 24 S
 iemens, “Stepping up the pace in vaccine 20, 2021.
or technologies. development and production,” 2021. 34 O ntology is a set of models for a particular
15 E
 quinor, “With a little help from my digital 25 The Economic Times, “Digital twin tech domain such as an IoT system or a building.
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16 Shell, “Shell develops digital talent and level: Gerd Hoefner, Siemens Healthcare,” graphs. Semantic technologies allow large
pioneers new virtual manufacturing November 2020. amounts of data to be managed efficiently
technology,” August 27, 2020. 26 Dassault Systemes, “The Living Heart and provide for data interoperability.
17 Honeywell, “Honeywell introduces Virtual Project,” accessed on February 25, 2022. 35 C
 apgemini Research Institute,
Reality-based simulator to optimize training 27 C apgemini Research Institute, “Conversations for Tomorrow #3,
for industrial workers,” October 26, 2020. “Conversations for Tomorrow #3, Intelligent Industry: The Next Era of
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strategy for battling climate change”, Transformation, Discussion with Kimberly- Clark,” December 2021.
March 2020. Clark,” 2021. 36 Microsoft news center, “Johnson
19 W orld Economic Forum, “How digital twins 28 T he Wall Street Journal, “Unilever uses Controls and Microsoft announce global
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 NV, “DNV creates Digital Twin for E.ON,”
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21 Neptune Energy, “Neptune Energy’s new 31 P
 R Newswire, “River Logic partners with 38 NS Energy, “Why France is developing
digital twins support Dutch New Energy Philip Morris International to create digital twins for the country’s nuclear
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22 C IO, “Rolls-Royce turns to digital twins to manufacturing network,” September 2020. 39 D igital Twin Consortium website, accessed
improve jet engine efficiency,” June 2021. 32 NVIDIA blogs, “NVIDIA, BMW blend reality, on January 4, 2022.
23 C apgemini Research Institute, virtual worlds to demonstrate factory of
“Conversations for Tomorrow #3, the future,” April 13, 2021.
Intelligent Industry: The Next Era of
References
Capgemini Research Institute 2022
51

Authors
Roshan Gya Jean-Pierre Petit Jacques Bacry
Managing Director, Global Head of Digital Manufacturing Group EVP Digital Continuity & PLM Group
Intelligent Industry Offer Leader, Capgemini Offer Leader
roshan.gya@capgemini.com jean-pierre.petit@sogeti.com jacques.bacry@capgemini.com

Brian Bronson Alexandre Capone Udo Lange


President and Managing Director, Vice President, Global Digital Head of Smart Products & New
Capgemini Engineering Americas Manufacturing Business Model, Capgemini Invent
and APAC alexandre.capone@capgemini.com udo.lange@capgemini.com
brian.bronson@capgemini.com

Verena Gertz Nicolas Croué Jacques Mezhrahid


Vice President, Digital Engineering Vice-President, PLM CTO & Head CTO, Smart Factory, Capgemini
& Product Lifecycle Management, of Digital Continuity, Capgemini Engineering
Capgemini Invent Engineering Jacques.mezhrahid@capgemini.com
verena.gertz@capgemini.com nicolas.croue@capgemini.com

Capgemini Research Institute 2022


52

Alex Berg Nithin Divakar Naik Elena Vasilyeva


Communications Lead, Capgemini Head, Digital Engineering and Digital Twin Offer Lead,
Engineering Americas and APAC R&D, Invent India Capgemini
alex.berg@capgemini.com nithin.naik@capgemini.com elena.vasilyeva@capgemini.com

Jerome Buvat Subrahmanyam Kanakadandi Ramya Krishna Puttur


Global Head of Research and Head Senior Director, Capgemini Assistant Director, Capgemini
of Capgemini Research Institute Research Institute Research Institute
jerome.buvat@capgemini.com subrahmanyam.kvj@capgemini.com ramya.puttur@capgemini.com

Shreya Pande
Manager, Capgemini Research
Institute
shreya.pande@capgemini.com

Authors
Capgemini Research Institute 2022
53

The authors would like to thank Moise Tignon, Louise


Barbolosi, Oliver Moron, Tobiah Master, Mike Dwyer, For more information,
Graham Upton, Neil White, James Forrest, Philippe
Vié, Jörg Junghanns, Ralf Bus, Cyrille Greffe, Pascal
Feillard, Michael Denis, Jean-Marie Lapeyre, Lee
please contact:
Beardmore, Frédéric Arquier, Karl Bjurström, Sanket
Solanki, Joyce W Chew, Walid Negm, Dietmar Wendt,
Benjamin Dawes, David Jackson, Nicolas Chanteloup, Global contact Regional contact
Mikhail Kazakov, Christophe Vidal, Ron Tolido, Simon
Pilhar, Matthias Maurer, Murali Chandrahasan, Julian Roshan Gya Frédéric Dispa
Fowler, Anton Turchenko, Camila Fierro, Olivier Global Head of Intelligent Industry Intelligent Industry Leader - Southern
Marcillaud, Ranjit Gangadharan, Thomas Zühlke, roshan.gya@capgemini.com & Central Europe
Baljeet Yadav, Somkalpa Laha, Srinivas Varanasi, frederic.dispa.externe@capgemini.com
Pritam Subba, and Kristin Morris for their contribution
to this research. Jean-Pierre Petit Mark Landry
Digital Manufacturing Group Offer Leader, Intelligent Industry Leader - Americas

About the Capgemini


Capgemini mark.landry@capgemini.com
jean-pierre.petit@sogeti.com

Research Institute
The Capgemini Research Institute is Capgemini’s Jacques Bacry Vikas Kumar
EVP Digital Continuity & PLM Group Intelligent Industry Leader - APAC
in-house think tank on all things digital. The
Offer Leader vikas.g.kumar@capgemini.com
Institute publishes research on the impact of jacques.bacry@capgemini.com
digital technologies on large traditional businesses.
The team draws on the worldwide network
of Capgemini experts and works closely with
Moise Tignon Udo Lange
academic and technology partners. The Institute VP, Intelligent Industry Digital Continuity Leader
has dedicated research centers in India, Singapore, moise.tignon@capgemini.com udo.lange@capgemini.com
the United Kingdom, and the United States. It was
recently ranked number one in the world for the
quality of its research by independent analysts.

Visit us at www.capgemini.com/researchinstitute/

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About Capgemini
Capgemini is a global leader in partnering with companies to transform and
manage their business by harnessing the power of technology. The Group is
guided everyday by its purpose of unleashing human energy through technology
for an inclusive and sustainable future. It is a responsible and diverse organization
of over 340,000 team members in more than 50 countries. With its strong
55-year heritage and deep industry expertise, Capgemini is trusted by its clients
to address the entire breadth of their business needs, from strategy and design
to operations, fueled by the fast evolving and innovative world of cloud, data, AI,
connectivity, software, digital engineering and platforms. The Group reported in
2021 global revenues of €18 billion.

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