Digital Twin Defined - The Update, Updated!

"If the digital came first shouldn't it be the Physical Twin?"

Update: 9-26-19

Again the term, digital twin, is more obscure than ever! Here is a self serving article by CIMdata President & CEO,  Peter A. Bilello

"Moreover, these production asset-focused digital twins and digital threads must be enabled with Product Lifecycle Management (PLM). PLM-enabled digital threads and digital twins promise to link the physical and digital worlds of manufacturing to a greater extent than ever before."

The operative word "Promise"

Engineering has been delivering the 3D model with the necessary AID (Associated Information Document) to manufacturing since 1988. This nothing new. It is hardly a digital twin it is basically a pattern for CNC. Many times you will not need the 3D model in the case of pre-formed parts such as standard tubes,  pipes and structural shapes. It is people like Peter that have not done their homework and do not understand how engineering to manufacturing works.

Digital Threads, Twins Play Catch-Up in the Factory

The Death of PLM

Engineering and Manufacturing

Many talk about a "digital thread" that links engineering to manufacturing. The only direct connection from engineering to manufacturing is "in stone" engineering documentation. Engineering and manufacturing operate at much different speeds. Engineering is infinite and manufacturing is finite. I have no idea why this has to be explained. When you decide to build an aircraft the engineering staff is in place long before the documentation is made available to manufacturing.

"Engineering's only purpose is to make available concise, complete and unambiguous documentation to manufacturing!"

Engineering releases completed engineering documentation to an archive that is easily accessible by manufacturing and any other department. Engineering may be called in on first article, after that, they are never called again unless there is a problem. Sadly, our engineering process is in the hands of the PLM guru and CIOs, with virtually no engineering documentation knowledge!

Engineering Documentation A Primer for the PLM Guru!

The Death of the Draftsman or “Where has all the talent gone?”

Update: 4-24-19

I wrote this article in December 2018. Things seemed to have focused on the factory and machine simulation led by Siemens.

For the life of me I don't understand the need for graphic representation for this process. I am sure the maintenance staff in any company have a compete understanding of the operations. It is obvious those that are pushing this do not know the process of creating 3D models. Even if the machine or factory is already modeled what kind of software is going to be able to handle the size of the model and work with it. You already have physical machines!

Let's go back to a time before computers. Yes, i know many of you don't even know there were times like that. I find this to be very interesting, I see those today that are not even interested how they did it before computers. I was there and it operated much simpler and more productive.

1. Before the computer there was a maintenance staff fully knowledgeable of the operation of the factory and any machines. The knew ever widget, motor and mechanism. They had the date a motor or other equipment were installed. They would know the recommended the lifecycle and have plans for replacement. They would do schedule inspections of the equipment. Hmm no computer overhead?

2. Let's add the computer. Now, we can add sensors to check wear. Now those will report to a display that shows the information on a monitor in the maintenance office. Motors or other wear items are still replaced at the end of their recommended lifecycle and they would still have physical scheduled inspections.

3. Now let create a digital twin! Uh, now you look at what? You still replace the motor at the recommend lifecycle. It is just so much fluff. You add a staff of InfoTech to monitor it. LOL The maintenance staff just chuckle.

Now lets add the cost.

First no computer over head, all of the reports were put on paper in specific folders and schedules. Clean, clear and precise!

Add the computer. You have a computer display and schedules are shown per the date required. Hmmm you just looked at a daily schedule before.  You are still doing your physical inspection. The sensors do not replace the scheduled inspection. Your reports are archived! LOL

Add the digital twin! You have a picture of the motor, widgets, mechanisms, etc with cool sensors. Hmmm Okay, how is that better than before? You still have a maintenance schedule and physical inspections. The sensors do not replace a scheduled inspections.

The maintenance staff are laughing at the InfoTech's sense of importance! But probably a bit miffed due to their budge being cut to support the waste of time "Digital Twin". I will guarantee that upper management did not consult the maintenance staff lead, he/she probably doesn't even have a smart phone!

The ROI on the Digital Twin? MINIMAL!!

So how much does this Digital Transformation cost?

Call Siemens today!! LOL

It is funny to me, in the past the industries were the experts in their field. Now the InfoTech companies like Siemens, Rockwell, Dassault, PTC, etc. have convinced huge companies, like Boeing and many other industries they know how to run their operations better? Go Figure!

Digital Transformation - 70% Failure! $900 Billion Wasted!

Back to the original article.

Now I have seen three definitions. I am sure these examples cover the whole subject.

The first was an explanation of the digital twinning basically as “computer simulations”.

Now if I say to you, we are doing some “Digital Twinning” what would come to mind?

Not much,  you would need much more information to explain what is going on.

But if I said we are doing some “Computer Simulations” you would instantly know what I was talking about. So why “Digital Twinning”?

Here is an example of the first definition both basically related to computer simulations.

David Vasko   
Director Advanced Technology at Rockwell Automation (David is no fool)

"You had asked about what value digital twins provide.  It is a good question.  For me, the digital twin must be living.  It is a is a digital replica of a physical asset, process or system. It is a living simulation model used to provide insights. This living simulation model can be used to provide insights into the behavior of devices, machines or enterprises in the design, operate or maintenance phases. This provides real value.