Manufacturing plants are complex in nature. Changes in a product or introduction of new products to market are frequent. Also, order, process flow, inventory, logistics and resources keep changing. Plant Managers within different departments end up spending a lot of effort and time to implement these changes, which affects the production process, throughput, cost, and time.
How can IoT help?
IoT can be embedded in a large number of applications in manufacturing plants. It helps in understanding and simplifying the process flow, tracking the products, managing the work in process, balancing the line, and optimizing the material flow movement in the warehouse as well as the inventory level. It can collect enormous amount of data in real time based on the number of sensors and devices attached.
What can Digital Twin do?
Digital Twin tool replicates the real-world system in the virtual machine to predict the effect of changes on existing systems and can also analyze the quality and performance of new systems. Through a virtual model, it can help identify defects, and predict the end of life of a product. Digital Twins can make production efficient, reduce time to market for new products, and help bring down maintenance costs.
What happens when IoT and Digital Twin come together?
The collected data from IoT can be integrated with the Digital Twin tool to analyze the effectiveness, efficiency and accuracy of the system without affecting the real-world system. Digital Twin can collect the information from IoT sensors, and conduct a series of repeated trial-and-error experiments for the purpose of either understanding the behavior of the system and/or evaluating various strategies for operation of the system.