Digital Twin
A digital twin in manufacturing is a comprehensive virtual representation of a physical product, process, or system that mirrors its real-world counterpart in real-time. This dynamic digital model integrates data from sensors, IoT devices, and other sources to accurately reflect the current state, behavior, and performance of its physical twin
What is IndustryOS™?
IndustyOS™ is a comprehensive digital platform developed to drive digital transformation in industrial operations and supply chain management. Designed as an “Industry Operating System,” it serves as an integrated ecosystem for managing factories and commercial facilities by bridging physical operations with digital tools.
Components of IndustryOS™
IndustryOS™ Data Suite Software
Centralized platform for managing and analyzing industrial data efficiently.
IndustryOS™ Process Software
Optimize and streamline manufacturing processes for peak efficiency.
IndustryOS™ EHS Software
Ensure workplace safety, compliance, and sustainability with intuitive tools.
IndustryOS™ Maintenance Software
Proactive maintenance management to minimize downtime and maximize equipment lifespan.
IndustryOS™ PSM Software
Comprehensive process safety management ensuring operational risk mitigation.
IndustryOS™ Operations Software
Real-time operational insights to drive efficiency and informed decisions.
GHG Accounting & Assurance Software
Track, calculate, and assure greenhouse gas emissions with precision.
Importance of Digital Twins
-
Virtual Prototyping Factories often collect vast amounts of raw data but fail to systematically tag it with operational context, rendering it less actionable. Digital Twin helps you organize all your information including P&IDs, equipment layouts, plot plans, BOM etc.
-
Predictive Maintenance Analyze equipment sensor data to forecast failures 20-30% earlier, reducing unplanned downtime by 70% and maintenance costs by 25%. For example, Bosch uses digital twins to flag machinery deviations, improving system reliability.
-
Real-Time Process Optimization Monitor production lines via IoT sensors to identify bottlenecks (e.g., cycle time delays) and adjust workflows dynamically.
-
Quality Control Enhancement Simulate extreme operating conditions (e.g., temperature/pressure variations) to detect design flaws pre-production.
-
Remote Monitoring & Collaboration Provide stakeholders with a unified platform for 24/7 data access, enabling faster cross-departmental decisions.
-
Sustainability Compliance Track carbon footprint metrics across production stages, identifying areas to reduce emissions by 12-15%. EDF uses this for eco-friendly nuclear plant designs.
What is iLOL™?
IndustyOS™ helps Industries outlay Information over a layout. It creates a base over which data is layered onto. You can choose from more than 450+ assets and model them into your own virtual factory representing factual locations and outlay advanced real time information over the layout. It helps you to design even granular details like piping’s, detailed P&ID’s, Cables, instrumentations etc. It helps you enable enormous logic to decision making, analytics and boundary definitions over which you can draw analytics.
Leveraging Data Twin
Data is the bedrock of modern decision-making, driving success at every level of industry. By integrating a digital twin with IndustryOS™, you unlock the power to effortlessly organize and digitize data, creating an advanced virtual model of your factory. IndustryOS™ empowers you to elevate key metrics like MTTR, MTBF, and OEE, while enabling real-time data visualization, AI-powered analytics, and predictive maintenance to dramatically reduce downtime and optimize performance. This transformative combination not only supercharges operational efficiency but also accelerates your progress toward sustainability, compliance, and EHS excellence—propelling you forward on the fast track to manufacturing excellence.
Static Data
Static data includes unchanging foundational information such as machine layouts, hazardous area maps, and equipment specifications. It ensures standardization, regulatory compliance, and a reliable baseline for advanced analytics and process improvements.
Workflows
Workflows are human-initiated or automated actions like task tracking, KPI updates, audits, and checklist generation. These workflows are digitally orchestrated to ensure adaptive processes, accountability, and seamless operational flow.
Dynamic Data (Real-Time Data)
Dynamic data captures real-time information from IoT sensors, machines, and operator inputs. It empowers predictive maintenance, live performance monitoring, and agile decision-making, bridging physical operations with intelligent systems
Features
Factory Function – OEE, Production, Maintenance
Consolidates factory operations, including OEE monitoring, production oversight, and maintenance tracking, into a smart, connected system.
iLOL™
Locates information at their factual geo-location creating virtual factories which helps to create a base over which information and analysis can be layered onto.
Static Data
Transforms static asset data into an organized, actionable digital repository, ensuring better insights and operational efficiency.
Machine and People Integration
Seamlessly connects machines and workforce into a cohesive digital system, driving collaboration and enhancing productivity.
EHS Integration Integrates
Environment, Health, and Safety processes into a digital platform, ensuring compliance and proactive risk management.
Process and BOP Interconnection
Links processes with the Balance of Plant digitally, enabling synchronized workflows and greater precision in execution.
Digital Connect and Sensor Integration
Incorporates IoT and sensor-based connectivity, delivering real-time insights and enabling smarter, predictive industrial operations.