Digital twin is a technology that uses digital technology to collect data in physical space and recreate the real world in virtual space “like a twin.” By using technologies such as AI and IoT, we simulate the future by acquiring data on places, people, things, etc. and recreating it in virtual space.
In this article, we will introduce digital twins in detail, including their benefits and usage examples.
What is a digital twin?
For example, by using digital twins to collect and analyze data related to problems in real time, it is possible to quickly correct the cause. In addition, by accumulating data that reflects usage status in a virtual space, it becomes easier to improve products. In this chapter, we will explain in detail what a digital twin is.
Digital twin is a technology that creates a copy of the real world in virtual space.
Digital twin is one of the latest technologies that is attracting attention in the manufacturing industry. This technology can reproduce physical elements such as real-world products and equipment in a virtual space.
There are many benefits to introducing this technology, but the major one is that it can improve the efficiency and productivity of equipment. Specifically, it helps troubleshoot and prevent maintenance on production lines. It can also be used for product quality control and new product development.
Ministry of Internal Affairs and Communications’ digital twin initiatives
The Ministry of Internal Affairs and Communications is proceeding with the construction of digital twins for local government facilities and buildings. This initiative is expected to enable disaster response and efficient facility management.
In the manufacturing industry, in addition to optimizing manufacturing processes, it can be used in various aspects such as quality control and new product development. Therefore, digital twins will become an increasingly important technology in the manufacturing industry in the future. In addition, it is expected that by being used in the public sector, as in the case of the Ministry of Internal Affairs and Communications, it will contribute to improving the efficiency of society as a whole.
Differences between digital twin, simulation, and metaverse
Some people may be confused because there are many similar concepts such as digital twin, simulation, and metaverse. From here, I will explain the differences between digital twins and other concepts.
How is it different from simulation?
Simulation refers to recreating what is happening in real space in another location. On the other hand, digital twin can be said to be a method of simulation, but the difference is that it is done in real time. Digital twins can be recreated in virtual space in real time. This makes it possible to instantly grasp the situation in real space with high precision and perform appropriate simulations.
Digital twins can be used to optimize product design and manufacturing processes before the actual car is manufactured. It is also possible to improve productivity by simulating the settings and operation methods of production line equipment.
How is it different from the Metaverse?
Digital twins can be used efficiently in product development, manufacturing, and maintenance by creating a physical model of a product or process and simulating its operation and behavior . On the other hand, the Metaverse is a virtual space that does not necessarily correspond to the real world and is used for various purposes such as business and entertainment.
In the manufacturing industry, the Metaverse is used in a variety of ways, such as virtually designing and simulating products on the Metaverse, or building a digital twin factory on the Metaverse to reproduce a production line and simulate it in real time.
5 benefits of digital twins in the manufacturing industry
Digital twins bring five benefits to the manufacturing industry:
- Improving production efficiency
- Strengthening quality control
- Development cost reduction
- Realizing on-demand production
- Supply chain optimization
Advantage 1. Improved production efficiency
By introducing a digital twin, it is possible to quickly create a highly accurate virtual model of a production line and design an optimal production process. This eliminates the need for time-consuming repetition of conventional trial-and-error improvement work, and is expected to improve production efficiency. In addition, since the entire production line can be understood, it leads to smooth coordination between processes and automation of work.
Advantage 2. Strengthening quality control
This makes it possible to detect abnormal values and defective areas during quality control and take prompt action. Furthermore, with the introduction of digital twins, quality control work that previously required on-site observation and measurement may become faster and more accurate.
Advantage 3: Reduced development costs
Utilizing digital twins can reduce the number of prototypes and prototypes required for product development. Additionally, by simulating product design and production processes, problems can be discovered and improved at an early stage during the development stage. This will make it possible to reduce development costs.
Advantage 4. Realization of on-demand production
By leveraging digital twins, you can achieve fast and flexible on-demand production. In conventional manufacturing, production lines were often designed for mass production, so small-lot production and customized production tended to be time-consuming and costly. However, by using a digital twin, product design and manufacturing processes can be virtually reproduced, making it possible to quickly and easily make design changes and optimize production lines. This allows us to handle small-lot and customized production, allowing us to respond more flexibly to customer needs.
Benefit 5. Supply chain optimization
Supply chain optimization is possible by utilizing digital twins. The supply chain is the flow from the procurement of raw materials to the shipment of products, and is a complex process that involves many elements such as production lines, logistics, and inventory.
By using a digital twin, data on each element can be collected and reproduced virtually, making it possible to improve the efficiency of the entire supply chain, such as inventory optimization and production line optimization. In addition, visualization of logistics and inventory will improve the accuracy of demand forecasting and inventory management, which will also lead to cost reductions.
Examples of digital twin usage in the manufacturing industry
It would be a good idea to refer to case studies when actually implementing digital twins. You can compare the points you can incorporate in your company in the future with specific plans.
Toyota | Used in demonstration experiments in smart cities
The aim is to build a smart city where cars, energy, buildings, etc. are linked, and digital twins are used for simulations by reproducing equipment such as vehicles and energy systems in virtual space. Based on this result, we were able to work on the development of self-driving cars and improve Toyota’s technological capabilities.
Renault | Used to improve efficiency of vehicle development process
Renault uses digital twins to streamline its vehicle development process. Using digital twins, it is now possible to perform verification and evaluation in a virtual space during the product development process.
Specifically, we use 3D digital twins to consistently manage everything from product development to manufacturing and maintenance. This makes it possible to optimize designs and production lines, contributing to shorter development times and lower costs.
Daikin Industries | Utilizing to create a “factory that never stops”
Daikin Industries is currently using digital twins to create a “non-stop factory” (a factory that minimizes production line stagnation). Using digital twins, we are working to predict and improve production line stagnation in factories and improve production efficiency. We reproduce the conditions of manufacturing equipment and assembly work in virtual space to monitor and troubleshoot production lines.
It can be said that the introduction of digital twins has minimized production line downtime and improved productivity.
DENSO｜Used to realize Maas
DENSO is working to realize MaaS (Mobility as a Service) services by utilizing digital twins. Specifically, the purpose is to provide appropriate services based on vehicle driving data and customer information, and to improve customer satisfaction. Utilizing digital twins enables more efficient vehicle management, leading to the provision of MaaS services.
Services that utilize digital twins | What is the supply chain optimization (SCO) service provided by Hitachi?
In the manufacturing industry, digital twins are a hot technology for optimizing supply chains and improving production efficiency. Hitachi’s supply chain optimization (SCO) services utilize digital twins to improve supply chain efficiency, reduce costs, shorten lead times, optimize inventory, and improve customer service. What is attracting attention is that it is possible to simulate “production, logistics, and sales” as a set, rather than just production or logistics alone.
Specifically, we will reproduce the entire product cycle as a digital twin and optimize every step of the way, including product design, manufacturing, sales, and after-sales service. In addition, by collecting information on product inventory and logistics in real time and performing simulations on digital twins, we can improve supply chain efficiency and reduce costs.
Technologies used in digital twin
Digital twins in the manufacturing industry utilize IoT, AI, 5G, VR, etc. to improve production processes.
[IoT] for data collection
IoT is a technology primarily used to collect data in digital twins. By attaching cameras and sensors to machines and products on the production line, data on product conditions and production processes can be collected from factory equipment and equipment in real time. This allows it to be used in a wide variety of applications, such as product quality control and production process optimization.
For example, food manufacturers may use IoT to collect information such as product temperature, humidity, and vibration in real time to ensure product quality.
With the introduction of IoT, tasks that were previously done manually can be automated and more efficient production processes can be realized.
[AI] for data analysis
AI is a technology that collects collected data, learns from it, and performs advanced data analysis to identify problems and suggest improvements. By analyzing the data collected by IoT, it is possible to optimize production processes and predict problems.
For example, there are cases where AI is used to analyze production line data and predict and respond to the occurrence of defective products in advance, leading to improved production line efficiency and quality. The introduction of AI can significantly reduce the time it takes to analyze data and solve problems.
[5G] for sending and receiving data in real time
5G is a next-generation communication standard that enables high-speed and stable communication, and is a technology for performing advanced data analysis. In the manufacturing industry, equipment, robots, sensors, etc. in the factory may be required to send and receive data in real time. Utilizing 5G will enable high-speed and stable communications, making it possible to remotely control devices and achieve advanced automation.
For example, there is a case where remote operations using 5G were used to remotely carry out work in offshore oil fields, successfully reducing the number of personnel. The introduction of 5G will enable rapid response in product quality control and production line optimization.
[VR] for visualizing digital space
VR is a technology that enables more effective decision-making, such as digital twin simulation and troubleshooting, by visualizing digital space. In the manufacturing industry, factory equipment and processes can be reproduced and visually confirmed in 3D space.
For example, VR can be used to simulate the design and layout of equipment in a factory, leading to improved productivity and reduced manpower. Additionally, troubleshooting, which previously required manual on-site work, will now be able to be done remotely.
[Blockchain] for storing data safely and transparently
Blockchain is a digital technology that uses distributed ledger technology to store information securely and transparently, and to prevent tampering. Multiple computers distributed on the network approve transaction information and data, and the information is prevented from being tampered with by storing it in a chain-like data structure that connects collections of data called blocks.
Also, because it is on a network, there is no centralized administrator. This makes it highly secure and reliable, and is used in a variety of fields. Although it is known to be mainly used for virtual currency transactions, it is a technology that is expected to be applied in many other fields such as contract automation, voting systems, and supply chain management.
Digital Twin Introduction | Two Challenges
Digital twin is a technology that will bring about major changes in the manufacturing industry, but there are several challenges to implementing it. Above all, let’s consider the balance between implementation costs and ROI improvement, as well as security issues.
Balance between implementation cost and ROI improvement
Implementing a digital twin can be expensive. Therefore, when companies decide to introduce it, they need to consider the balance between implementation costs and ROI (Return On Investment). On the other hand, the introduction of digital twins can improve productivity, improve quality, and detect failures early, and can be expected to have significant economic effects from a long-term perspective.
security issues
With the introduction of digital twins, security issues are also emerging. Digital twins enable real-time monitoring of products and systems, making them potential targets for hackers and cyberattacks.
Future outlook for digital twins
In the manufacturing industry, where digital twins are attracting attention, collaboration between digital twins and metaverses is expected for the future. The impact that future technological advances will have on the manufacturing industry is also a hot topic.
Collaboration between digital twin and metaverse
The reason why digital twins and metaverses are expected to work together is that large-scale simulations that cannot be realized in the real world can be performed in virtual space. Using digital twin technology, it is possible to virtually reproduce real space in the Metaverse, which is expected to enable a realistic product experience.
For example, by linking detailed product design information provided by digital twins with virtual space display and operability provided by Metaverse, product design and performance improvements can be made more quickly and accurately.
Future technological advances and their impact on the manufacturing industry
As for the impact that future technological advances will have on the manufacturing industry, advances in technologies such as AI, IoT, blockchain, and 5G are expected to improve productivity, quality control, and supply chains in the manufacturing industry.
For example, automation using AI can make manufacturing processes more efficient and improve quality control, and blockchain can improve supply chain transparency, making the entire supply chain more efficient. can.
Summary
In the future, it is believed that the collaboration between digital twins and the metaverse, as well as advances in technologies such as AI, IoT, blockchain, and 5G, will make it possible for manufacturers to provide more efficient and high-quality products more quickly. However, it is also necessary to respond to new challenges and risks arising from technological advances, and it is important for the manufacturing industry to continue to respond to technological advances and achieve sustainable growth.