Download White Paper: immersive Visibility of Industrial Asset Health Using Digital Twin Technology

Introduction

Digital twin technology is at the core of Industry 4.0, which enfolds automation, data exchange, and manufacturing processes, producing endless opportunities for industries to grow.

A digital twin is a virtual representation of a physical asset that is virtually indistinguishable from its physical counterpart. It includes design and engineering details that describe its geometry, materials, components, and behavior or performance. It is a key component of the Industry 4.0 ecosystem, owned and managed by business stakeholders to provide secure storage, processing, and sharing of data within an architectural tier.

For OEMs

Validates system design to prove product digitally before building and accelerate prototyping to assist go-tomarket strategies.
Optimizes commissioning time by advance validation of machine response with operational logic.
Reduces failures during testing phase.

For plant owners and operators

Enhances operator training by virtual experience.
Simulates operations before deployment to avoid hazards and ensure human safety during operations.
Improves efficiency of maintenance team by enabling diagnosis support using AR experience.

Asset Maintenance

Save costs through delaying planned maintenance based on dynamic operational insights
Avoid unplanned downtime by proactive operational control
Improve asset utilization and efficiency

Virtual Sensors

Avoid CAPEX costs for additional sensor
Maximize information utilization from existing sensors
Get visibility into asset condition in remote areas, where sensor installation is challenging

Analytics

Predicts remaining asset life
Provides reliable insights by combining physics-based models and machine learning algorithms
Validates proposed operational changes before deployment

Augmented Reality

Diagnostics overlaid on a physical machine in an AR environment
Repair guidance using digital work instructions or 3D animations in an AR environment
Virtual operator training

Key Features of Digital Twin

3D Model: Digital representation of the equipment that can mimic properties and behaviors of a physical device.
Data Model: Standardized data model for connectivity, analytics, and visualization.
Simulation: Representation of a physical device in a simulation environment to study its behavior.
Analytics: Qualitative and quantitative techniques/processes based on measured properties of a physical device to enhance productivity and gain business insights.
Visualization: Graphical representation of the insights either on a supervisory screen or personal device.

Business Benefits

The growing adoption of Industry 4.0, which brings end-to-end value change with Industrial IoT and widespread digital transformation, is bringing a multitude of new technologies to the mainstream, including Digtial Twin.

Business benefits of a Digtial Twin:

Virtual prototyping: Test your product prior to manufacturing.
Better planning: Improve efficiency and productivity by managing assets in real time.
Predictive maintenance: Optimize asset utilization; reduce downtime and maintenance cost.
Better insights: Real-time optimization and decision-making based on sensor data.

Engineering Phase
(Plan and Build):

Digital product traceability: Provide universal data access around a view of product systems information, or the digital thread, from requirements to design, testing, manufacturing, and visibility into the behavior of products in the field.
Product design optimization: The digital definition of the product is enhanced with real-world performance data, informing simulation models to improve quality and integrity of designs.
Usage-based requirements: Analyze real-world product usage and condition data to inform feature and functionality requirements, improving fit to market and enabling value-added service offerings.

Manufacturing and Operations Phase (Operate):

Connected operation intelligence: Combine, analyze, and deliver insights from disparate and diverse silos of assets, operators, and enterprise systems into unified realtireal-timeme visibility of KPIs for increased operational performance and informed decision-making.
Dynamic step-by-step instructions: Connect factory assets and ERP/MES systems to provide role-based views via augmented reality or connected applications to deliver adaptive work instructions in context for increased operator productivity and improved production quality.
Connected quality and verifications: Validate the correct design iterations, systems requirements, and product checklists by comparing as-designed to as-configured data through the digital twin.

Maintenance and Services (Maintain):

Adaptive field service: Combine real-time and historical asset data to deliver asset-specific contextual work instructions via augmented reality experiences or connected applications for increased technician efficiency and first-time fix rate.
Predictive monitoring and service: Monitor connected products and assets for threshold anomalies with predictive analytics and provide real-time alerts to move from reactive to condition-based maintenance, and increase service levels.
Remote service: Enable remote access and service including remote software updates to increase product and asset uptime and reduce onsite service calls.

Industries Served

Aerospace & Defence

Communications

Medtech & Healthcare

Mining

Energy

Geospacial

Rail

Semiconductor

Industrial

Utilities

Oil & Gases

Automotive

Vehicle sensor data gives automotive OEMs and tier suppliers analytics from deployed fleets enabling OTA patching opportunities. Insurance providers adopting usage-based insurance (UBI) can leverage driver data for setting premiums and accident reconstruction.

Aerospace

Thousands of sensors on commercial planes stream asset data to better system servicing and operational status.

Healthcare

Connected medical systems and tools ensure product integrity and measure patient outcomes.

Manufacturing

Digital factory equipment and machinery increase uptime and production yield, while reducing repair and maintenance rates.

Oil and Gas

Remote rigs send health data minimizing routine inspections and servicing.

Rail

View of deployed locomotives and assets health better optimizes scheduling, reducing servicing time.

Utilities

Digital representation of systems on the power grid improves demand response functions and energy efficiency.

Conclusion

While digital technology is evolving rapidly and organizations are in a hurry to embrace it, early adopters need to be careful while defining their business strategies. They need to evaluate their maturity for processes, technology, and capabilities before they opt for technologies such as the twins.

Key considerations while working with a digital twin program:

Carefully define current and future requirements of each digital twin program, then choose modeling software and data management tools.
Identify the most critical assets and data required to create digital twins.
Create digital twins for the critical assets first to gain experience and prove value to business sponsors.
Factor in cybersecurity and other related risks due to the use of cloud and IoT platforms.
Examine the scalability of your digital twin solution.

About Cyient

Cyient (Estd: 1991, NSE: CYIENT) is a leading global engineering and technology solutions company. We are a Design, Build, and Maintain partner for leading organizations worldwide. We leverage digital technologies, advanced analytics capabilities, and our domain knowledge and technical expertise, to solve complex business problems.

We partner with customers to operate as part of their extended team in ways that best suit their organization’s culture and requirements. Our industry focus includes aerospace and defense, healthcare, telecommunications, rail transportation, semiconductor, geospatial, industrial, and energy. We are committed to designing tomorrow together with our stakeholders and being a culturally inclusive, socially responsible, and environmentally sustainable organization.

For more information, please visit www.cyient.com

immersive Visibility of Industrial Asset Health Using Digital Twin Technology