Digital twins are more than just a trend. They are the key to efficient, data-based production and logistics. SDZ supports you in exploiting the full potential of this technology, from simulation to real-time emulation. Our solutions improve transparency, responsiveness and the basis for decision-making in complex processes. Find out on this page what a digital twin is, how it works and how you can use it specifically in your company.
Digital twin – virtual representation of production and logistics in real time
For us, a digital twin is more than just a simulation model; it connects real IT systems with virtual models and enables them to communicate in real time. This creates powerful tools such as emulation or real-time models that can be used to virtually test, analyze and optimize processes before they are actually implemented.
Mastering Complexity: A digital twin becomes particularly sophisticated when it interacts with real control and IT systems as a real-time capable process image. This creates an innovative system that can be actively used in operations, for example to monitor performance data, create transparency for operating processes and detect errors at an early stage. SDZ develops such real-time twins and implements them for operational use in practice.
For us, the digital twin is a practice-oriented tool for improving production. We use it like a magnifying glass to create an awareness of the technical challenges in internal processes. Without this digital view of operational processes, the necessary adjustments and improvements would be delayed or not noticed at all. With the digital twin, production processes can be specifically analyzed and positively optimized in the following areas:
How can we expand capacities? Are there any unused reserves? What is necessary to react flexibly to market developments?
In direct discussions with customers, it becomes clear time and again that many find it difficult to set clear objectives for the use of a digital twin. There are two reasons for this. Firstly, part of the optimization potential often only becomes visible when it is actually applied. Secondly, planning in many companies is based heavily on experience and intuition – and less on data-based analyses.
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To create a digital twin of your production, we use our own software SimAL.Suite, among other things. This allows us to define an individual objective for your company, tailored precisely to your requirements.
Our customers use the resulting digital twin of production in a variety of ways, for example:
It would be nice: An SDZ employee comes by, connects his laptop and immediately tells you what needs to be optimized in production and under what conditions.
The reality is different: Well-founded optimization requires not only technical expertise, but also a careful analysis of different but typical operating situations. Only on this basis can concrete and sustainable improvements be derived.
The digital twin is a technology that offers enormous potential for process optimization across all industries. Whether in industry, healthcare or retail, digital twins have established themselves as powerful tools for increasing efficiency, transparency and agility. In the following, we show how digital twins are used in different industries and what advantages they offer in these areas.
SDZ develops and implements digital twins for production and logistics. With digital images of real processes, we create the basis for well-founded planning and optimization decisions.
A team of experts consisting of process consultants, simulation experts and software developers analyzes existing structures and processes in production and logistics together with the client. Based on this, we develop customized simulation models as virtual twins for specific use cases.
After successful modelling and optimization, we transfer the simulation models into fully integrated digital twins. These are integrated into your existing IT landscape, e.g. via interfaces to ERP systems such as SAP, in order to use relevant data in real time. We provide your employees with comprehensive training to ensure efficient and safe use in day-to-day operations.
Our digital twins support the planning and optimization of production, from production design to operational implementation:
For planning & optimization of production:
Emulation (simulation-based test environment):
SimAL:
SDZ initially analyzed and optimized the production structures at various locations for a manufacturer of semiconductors. For this purpose, simulation models were created which, in addition to the automated production processes (production, internal material transport), also included the mapping of the operating strategies of the production IT (for controlling production). In a second step, the simulation models were coupled with the existing production IT systems and implemented as digital twins of production.
They are used as a test environment to check and optimize changes and the further development of the production structure. But also to determine the effects of changes to the production program. The use of the digital twins is still supported by SDZ today.
Benefits for our customers:
“The implementation of the digital twin has made us more efficient. We appreciate the collaboration with SDZ.”
Klaus M., Production Manager, Automotive Industry
“We were particularly impressed by the integration of the SimAL.suite, we achieved significant improvements in a short space of time.”
Martina R., Manager, Production facility
“The digital twin has helped us to identify unused capacities and optimize processes sustainably. SDZ was a reliable partner at eye level.”
Peter S., Managing Director, Mechanical Engineering Industry
A digital twin is a virtual image of a physical object or process that is linked to it in real time. It makes it possible to simulate, monitor and optimize real processes before changes are made in the real world. In production, the digital twin can be used to optimize machines, processes and resources.
A digital twin offers numerous advantages:
The digital twin can be implemented in many different ways, depending on the industry and objectives. In production, it can be used to simulate machine and process optimization. SDZ develops customized solutions that are precisely tailored to your company’s requirements.
One of the tools we use to implement a digital twin is our own simulation software SimAL.Suite. This software enables individual, demand-oriented simulation that can be connected to your control systems in real time in order to improve production processes. We use Plant Simulation for emulations.
The duration of the implementation depends on the complexity of the processes in your company. As a rule, the introduction of a digital twin takes between some weeks and a few months. As a first step, we work together to set objectives and start collecting data to develop the simulation.
The digital twin is particularly useful for companies in production and in the context of IoT in production (Industry 4.0). Small and medium-sized companies also benefit from the optimization potential, as they can use simulations to make processes more efficient and make better use of resources. The adaptability of the digital twin enables it to be used in a wide range of industries.
The cost of implementing a digital twin depends on the individual requirements. We offer you a consultation to clarify the scope and expected costs in detail. You are welcome to take advantage of our offer for a non-binding initial consultation.
To create a digital twin, we first need data from your production or logistics processes. This includes data from machines, processes and the control system, which is fed into the simulation software. The more relevant data is available, the more precise and useful the digital twin will be.
Yes, the digital twin is scalable and can be expanded as required. As soon as your business requirements change or new processes are added, we can adapt the digital twin accordingly. The flexible system enables continuous improvements and expansions.
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