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Digital twin technology has gained popularity among large manufacturers in the automotive and industrial engineering sector due to its ability to save time and optimize plant effectiveness. While smaller manufacturing firms have been slow to adopt this technology, they are starting to recognize the value it can bring regardless of their business size.

A digital twin is a digital representation of a real-world system, such as a factory, plant, mine, or resource. It allows manufacturers to acquire data and insights from the physical system, enabling them to update their distribution models. On the other hand, virtual twins provide a more dynamic look at factory systems, allowing businesses to visualize and simulate sophisticated experiences. Virtual twins show manufacturers what can be executed and implemented in the real world, providing actionable solutions to improve efficiencies.

Both digital and virtual twin technology can benefit almost any manufacturing organization, regardless of its size. Initially, digital twins were adopted in industries such as automotive, industrial equipment, and oil and gas, where the insights they provided streamlined processes and improved efficiency. More recently, manufacturing and life sciences markets have recognized the benefits of digital twins for their ability to provide sophisticated models.

Having digital or virtual twins integrated into manufacturing workflows can offer several benefits. These include saving time and costs, increasing employee safety, and optimizing resource allocation. As manufacturing industries become more complex, digital and virtual twin technology simplifies operations and enables manufacturers to make necessary changes quickly. This is particularly important in light of supply chain issues that affect many manufacturers worldwide.

In one case study, the installation of a virtual twin led to a 250% increase in plant effectiveness by identifying and analyzing inefficiencies. Another company saw a 50% increase in on-time deliveries and a 50% reduction in lead times, resulting in higher order fulfillment and improved customer satisfaction.

In summary, digital and virtual twin technology is becoming a staple across industries due to the numerous benefits they offer. Manufacturers, especially in manufacturing and logistics sectors, can benefit from reduced lead times and improved planning efficiency. Adopting these technologies not only enhances productivity but also enables sustainable manufacturing practices and ensures employee safety.

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