How a digital twin reduces errors
Production downtimes are one of the biggest challenges in the manufacturing industry. They cause immense financial losses, jeopardize adherence to delivery deadlines and put a strain on customer relationships. To counter these risks, virtual commissioning and the resulting digital twin offer opportunities to drastically reduce errors in planning and production.
Causes and consequences of production stoppages
There are many reasons for production downtimes and they affect different departments within a company.
Technical faults Machine or system failures are one of the most common causes of production downtime. This can be due to wear and tear, lack of maintenance or unexpected technical defects. The result: delays and often considerable repair costs.
Staff shortages Sickness-related absences, inadequate training or a lack of skilled workers can lead to machines not being operated properly. Especially in highly automated processes, qualified personnel are essential for smooth operation.
Quality problems Faulty products or a high reject rate can bring the entire production process to a standstill. The causes range from incorrect machine settings to faulty raw materials.
Planning errors Miscalculations in production planning, such as overly optimistic capacity planning or incorrect time specifications, can lead to considerable bottlenecks. A sudden increase in demand, for example, cannot be covered if production cannot react flexibly.
IT failures In an increasingly digitalized world, IT systems are a central component of production control. Cyberattacks or technical problems in the production software can paralyze entire plants.
Digital twin as a solution approach
Virtual commissioning is an approach for identifying potential errors at an early stage and minimizing production downtimes. iPhysics offers powerful simulation software that can optimize the entire development and production process, starting with the initial idea. Based on CAD data and linked to real control systems, the digital twin offers many advantages, and not just in engineering.
Advantages of virtual commissioning to avoid production downtime
- Early error detection: Technical weaknesses and planning errors can be identified and rectified during the simulation phase. This reduces unplanned downtimes in real production.
- Optimization of planning: Simulation allows time and capacity plans to be made more realistic, which reduces the risk of overloads.
- Better preparation of personnel: The virtual environment offers opportunities to train employees so that they become more confident in handling the systems.
Possible applications of a digital twin in production
Lock-ahead simulation
With the help of look-ahead simulations, machine concepts can be tested realistically as early as the planning phase. These simulations make it possible to identify and solve problems at an early stage before they can affect production. This speeds up commissioning and makes it safer.
Real-time monitoring
Digital twins are another key technology. They enable real-time monitoring and fast, proactive troubleshooting during operation. This allows potential problems to be resolved before production is interrupted, but also helps to find solutions to existing problems.
Remote Maintenance
A digital twin supports remote maintenance by providing a digital, virtual image of a physical machine or even a process. With the help of the digital twin, detailed analysis, monitoring and control can be carried out remotely, making maintenance more efficient and precise.
- Predictive maintenance: With the help of sensor data and advanced analyses, the digital twin can make predictions about the condition of machines. This allows maintenance work to be carried out in good time, which increases the service life of the systems and minimizes unscheduled downtime.
- Efficient fault diagnosis: In the event of faults, the digital twin provides a detailed analysis of the problem. Technicians can access the data remotely and initiate specific solution steps without having to be on site.
- Cost and time savings: Remote maintenance eliminates the need to send technicians to the site immediately. This saves time and travel costs and ensures faster problem resolution.
Limits of the digital twin
Even if virtual commissioning offers numerous advantages, not all problems in the production process can be solved with it. For example:
- Unforeseen technical faults: Wear and tear and spontaneous defects cannot be fully simulated.
- Cyber attacks: Simulation does not protect against targeted attacks on IT systems.
- Human error: Unexpected operating errors or a lack of communication within the team are factors that cannot always be taken into account in advance.
- Delivery problems and other
Summary
Virtual commissioning is not a panacea, but it is a decisive step towards reducing the frequency and severity of production downtimes. It offers companies the opportunity to identify technical and planning errors in advance and make production more efficient. Nevertheless, it remains important to be prepared for unforeseeable events and to be able to react flexibly to them.
With a balanced combination of virtual simulations, solid maintenance and well-trained personnel, the probability of production downtime can be significantly reduced.
Interested in discovering more about iPhysics? Request a brochure now!
Links to the website
General link:
Learn more about iPhysics and our virtual commissioning solutions on our website: www.machineering.com.
Directly to the product page:
Discover iPhysics – your solution for cloud-based simulation: www.machineering.com/en/products/iphysics
Contact page:
Do you have any questions? Contact us for more information: www.machineering.com/en/contact
Overview of VIBN:
Find out more about virtual commissioning and its benefits here www.machineering.com/en/virtual-commissioning
