Tag: Digital twin technology

What Is the Best IR4 Technology to Get Faster ROI From Digital Transformation?

Posted on by Neewee

Holistic digital transformation (DX) is the implementation of digital technologies in all areas of your manufacturing business, resulting in fundamental changes to how your organization operates and delivers value to customers. It’s a radical change that challenges the status quo, urging you to get comfortable utilizing production data and advanced technologies at all manufacturing levels. Simply put, holistic digital transformation extends beyond digitizing existing processes. It encompasses deploying digital technologies to enable new business models and enhance revenue streams. The underlined objective is improved business efficiency, cost reduction, and delivering value to customers.

The Current State of Affairs—

Why are Manufacturing Companies Struggling to Get ROI from Digital Transformation?

The term “digital transformation” is often used interchangeably with “smart manufacturing” or “Industry 4.0”. However, while all three terms are related, they are not the same. Smart manufacturing may be better understood as the outcome of holistic digital transformation. It involves the application of Industry 4.0 technologies to manufacturing processes for improved operational efficiency, quality product delivery, and flexibility in production planning.

Recently McKinsey reported Industry 4.0 technologies can unlock significant value across multiple areas of a factory network. [1] 30% of manufacturers plan to invest more in digital transformation in 2022. Most manufacturers measure the positive effects of digital transformation in terms of ROI and reduced costs. [2]

However, according to the McKinsey study, a massive 70% fail to capture full value from their digital initiatives because the companies:

  • approach digital transformation in a siloed manner.
  • are focused on isolated implementation of certain technologies and not planning a holistic framework,
  • do not align their digital initiatives with their unique manufacturing goals.

Where to go from here? —

Digital Twin Technology and AI/ML as Potential Solution for Manufacturing Companies to Get Faster ROI.

Manufacturers are now spoilt for choice when it comes to exciting options in technologies for Smart manufacturing. But are you making the right decision that will help you reach your specific manufacturing goals? The question of the day is; are you picking a technological solution that is customized to your needs? To whom does your organization turn for trusted technology solutions that are designed to solve YOUR specific manufacturing problems?

Soon, AI/ML will likely take the driver’s seat in the digitalization of manufacturing companies. Many industry experts agree that the “Digital Twin” technology will accelerate this change. A digital twin is a virtual replica of every machine, process, and product in your entire manufacturing system. An end-to-end simulation of the manufacturing value chain in real-time enables the production planners to visualize outcomes and foresee shopfloor events.

Additionally, when ML-driven AI is deployed, you get accurate actionable insights and timely recommendations for building optimized production models. Based on advanced data analytics, you can adjust parameters to create multiple versions and arrive at the best plan that promises process efficiency and overall improved production.   

Neewee’s Digital Twin and AI/ML technology have the potential to revolutionize the manufacturing industry. Companies can get faster ROI on their digital transformation investments as our AI eliminates manual experimentation and provides data-powered algorithmically driven real-time solutions. Accurate data visualization enables informed decision-making that can optimize resource and capacity utilization.

Companies that produce high-quality products efficiently always deliver 2X customer satisfaction. In other words, if a company can manufacture products quickly and without defects, it has enhanced productivity, which will ensure it retains and grows its customer base. While it may seem like common sense that such a favorable situation translates into ROI, it is not always easy. Any manufacturer would be able to share how new challenges keep cropping up and hidden factors impacting performance can become difficult to identify.

Neewee’s AI/ML technology solutions help companies overcome challenges and maintain production efficiency to ensure that they are able to deliver 2X customer satisfaction on time and get faster ROI, every time!

References:

[1] Gregolinska, E., Khanam, R., Lefort, F., & Parthasarathy, P. (2022, April 13). Reaching scale in the Fourth Industrial Revolution | McKinsey. Www.mckinsey.com. https://www.mckinsey.com/business-functions/operations/our-insights/capturing-the-true-value-of-industry-four-point-zero

[2] Quixy. (2022, May 7). Top Digital Transformation Statistics in 2022 & beyond | Quixy. Quixy. https://quixy.com/blog/top-digital-transformation-statistics-trends-forecasts/

How to Unlock Connectivity for Holistic Digital Transformation of Manufacturing

Posted on by Neewee

How Neewee Streamlines Manufacturing Data Acquisition (DAQ)

“Connectivity” is the password for unlocking the holistic digital transformation of your manufacturing. There must be connectivity, not only between all the assets but also for all the processes in the entire manufacturing value chain. Neewee has always aimed at simplifying “connectivity” to streamline data acquisition and enhance customer experiences.

Different manufacturing systems require a different approach to collecting relevant production data. Several machines and processes are involved, and readiness of the equipment for connectivity differs.

At level zero, equipment resources such as sensors, actuators, and PLC transmit data. While at the next couple of manufacturing levels, Distributed Control System (DCS), Human Machine Interface (HMI), and the Supervisory Control and Data Acquisition (SCADA) or CNC machines for manufacturing systems act as the data sources.

Companies typically use an ERP (Enterprise Resources Planning) system for planning, supply chain, manufacturing, financials. While on shop floor or in plants manufacturers use information exchange standards such as OPC or MT Connect to streamline machine connectivity. In such cases, data acquisition can be simple by connecting to these systems.

In other cases, our Bodhee AI (Artificial Intelligence) apps are equipped to decipher a wide range of data sources. In addition, our range of IIOT devices called Rishee are used as data aggregators, smart controls, software connectors and gateways for continuous data communication.

“Information is in plenty, but intelligence is limited,

without seamless connectivity between machines and processes through all levels of manufacturing control systems.”

– Gucchu Gul Lalwani, Co-Founder & Chief Product Engineering, Neewee

Creating Seamless Connectivity in Processes and Machines

Harmonization of acquired data, in-depth diagnostic data analytics, and appropriate data visualization are essential for identifying and solving manufacturing problems.

Neewee’s Digital Twin technology makes the best use of the connectivity. Once multiple manufacturing assets and sub-processes data are linked together from end to end, a virtual replica gets created of every asset, component, and process in your entire manufacturing system. Digital Twin then facilitates the simulation of the LIVE production processes. Enhanced operational visibility provides the manufacturer with a clear understanding of the shop floor realities.

Integrated data analytics powered by AI and Machine learning algorithms then help identify the anomalies in the operations and assess improvement opportunities.

Monitor> Analyze> Control> Recommend

AI/ML-powered production monitoring and predictive analytics improve decision-making, enable process control, and provide actionable insights for process improvement.

 By aligning Neewee’s Digital Twin technology to the value you expect from your manufacturing processes, you can optimize production efficiency and enhance quality with a targeted approach.

To read in detail about the transformational impact Neewee’s Digital Twin technology can make on your manufacturing, you can read our previous post here (Back-to-Back Success for Neewee’s Digital Twin Technology. – Neewee)

Digital Transformation That Leads to Quantifiable Improvement

There will be a visible improvement in enterprise-wide performance. You can track and leverage key performance indicators (KPIs) to drive sustainable growth. Your manufacturing transformation is as efficient as the quantifiable factors indicate.

The Business Impact that Leads to $ Translation:

  • Reduced working capital by 8-10%
  • Enhanced product quality by 10-12%
  • Improved process yields by 8-10%
  • Improved production performance by 5-7%

Pick only the best holistic digital transformation strategy that guarantees quantifiable results.

Contact us. Let’s optimize!

References:

[1] Neewee. (n.d.-b). Neewee – Enlighten your Manufacturing. Optimize Manufacturing with AI Apps That Deliver Integrated Analytics. https://neewee.ai/

Back-to-Back Success for Neewee’s Digital Twin Technology.

Posted on by Neewee

Predicting manufacturing defects and malfunctions in the process.

In quick succession to our story of how Neewee got listed as a Digital Twin Operator in an influential business and technology report, here is yet another. We are elated by the newest feather in our metaphorical hat!

The “Smart Factory Trend Report”, distributed by the Japanese TECHBLITZ, lists eight categories of digitalization services that will shape the future of manufacturing. We are proud to share that Neewee features as a representative in the ‘Design & Simulation’ category for our Digital Twin technology.

An article published online as a summary of the report points out that AI-powered design data visualization delivers accuracy in simulation. It also improves the iterative process efficiency. All crucial for product development.

Read the overview of the full report published here. 8 CATEGORIES OF SMART FACTORIES THAT ARE THE FUTURE OF MANUFACTURING – TECHBLITZ

Transformational Impact Through Connectivity

The industrial internet of things (IIoT) is the ecosystem of devices, people, and processes that are connected and interoperable. To briefly define the Digital Twin, it is a virtual representation of all those physical objects and processes in the entire manufacturing value chain. IIoT enables the data collection from various sensors, and Neewee’s AI app helps process it in real-time. The digital twin creates simulations of every step in the production process, unlocking valuable insights that help improve decision-making. The digital twin technology optimizes process efficiency in different manufacturing areas—product design and production to marketing— impacting business outcomes significantly. Thus, the potential for increased productivity using digital twins is immense as it transforms the entire industrial operations into intelligent manufacturing.

Neewee’s Digital Twin Technology for Predictive Analytics and Monitoring Production Performance.

Manufacturing is a cost-intensive and time-sensitive process. Predictive analytics in manufacturing can help companies forecast process variations, reduce waste, and control costs. Predictive analytics can also help manufacturers improve quality and provide more personalized customer service.

Dynamic, data-powered simulation of the physical world with the digital twin technology is a boon for predictive analytics. Getting an organization-wide view of shop-floor realities is key to effective decision-making. Statistical and analytical models help production managers predict and control future events in the process workflow. Predictive analytics uncovers patterns in production data to detect dysfunctional processes, which can cause anomalies in the output. Manufacturers can mitigate such risks if they receive timely actionable insights.

The digital twin also helps forecast deviations or disturbances in the manufacturing process before they occur. For example, if it predicts an issue with the equipment, an alert gets sent out to the production team. That helps them fix the equipment before the issue escalates and becomes an actual problem. The production team gets saved from unexpected downtime, which could have caused delays in batch-cycle time. Thus, a digital twin operator can help manufacturers save money by preventing any small or big interruption of the production line. Aside from monitoring production performance and catalyzing production flexibility, predictive analytics with the digital twin supports maintenance tasks too.

By aligning Neewee’s Digital Twin to the value you expect from your manufacturing processes, you can optimize production efficiency and enhance quality with a targeted approach.

Gartner’s survey revealed Digital Twins are entering mainstream use. Benoit Lheureux, research vice president at Gartner said, “Over two-thirds of companies that have implemented IoT will have deployed at least one digital twin in production.” This rapid growth in adoption is because digital twins are delivering business value and have become part of digitalization strategies. [1]

On the other hand, Thomas Kaiser, SAP Senior Vice President of IoT said, “Digital twins are becoming a business imperative, covering the entire lifecycle of an asset or process, and forming the foundation for connected products and services. Companies that fail to respond will be left behind.” [2]

You do not want to be left behind. Act now! Book a Demo.

For those who missed the detailed enumeration of “What Is a Digital Twin?” and the value it brings to manufacturing, read our previous post here Forrester Lists Neewee Amongst Digital Twin Service Providers in 2022 Report – Neewee

References:

[1] STAMFORD, Conn. (2019, February 9). Gartner Survey Reveals Digital Twins Are Entering Mainstream Use. Gartner. https://www.gartner.com/en/newsroom/press-releases/2019-02-20-gartner-survey-reveals-digital-twins-are-entering-mai

[2] Marr, B. (2017, March 6). What Is Digital Twin Technology – And Why Is It So Important? Forbes. https://www.forbes.com/sites/bernardmarr/2017/03/06/what-is-digital-twin-technology-and-why-is-it-so-important/?sh=1b2ef4c52e2a

Forrester Lists Neewee Amongst Digital Twin Service Providers in 2022 Report

Posted on by Neewee

In the recent report published by Forrester, Now Tech: Digital Twin Service Providers, Q1 2022, which analyses the digital twin service provider market, vendors were listed based on market presence and functionality. The overview provides a list of digital twin service providers. All have been segmented into three categories based on digital twin solutions revenue—large established players (>$1,000 million in Annual Category Revenue), midsize players ($100 million to $1,000M in ACR), and smaller players (<$100M in ACR). Also, as per functionality, the market is divided into three segments. 

Neewee is honored to have been listed as a small vendor in the digital twin operator primary functionality segment with a vertical market focus on chemicals, pharmaceuticals, metals, aerospace, food, and beverage. Neewee is also proud to have provided information for the research, too.  

Tech execs must read Forrester’s full report now published here (available to Forrester subscribers and for purchase)

For those who would like to learn more about the digital twin, read on!

What Is a Digital Twin?

According to the Forrester Now Tech report, a digital twin is “a digital representation of a physical thing’s data, state, relationships, and behavior.” [1]

All the data of the physical counterpart—its state, relationships, and behavior—is taken in to create a virtual model. The link that forms the bidirectional loop of data between the physical manufacturing system and its digital model is called the Golden Thread. A cleverly deployed digital twin can turn your manufacturing towards productive and efficient processes.

Neewee’s Process Digital Twin

Industry 4.0. is all about the digital transformation of the manufacturing industry. However, for a holistic digital transformation of an entire facility, we need to consider the entire manufacturing value chain as a set of connected processes. Propagating connectivity is at the foundation of Neewee’s philosophy. To enable seamlessly efficient manufacturing, Neewee accordingly developed the AI apps. 

When a digital replica gets created, every manufacturing process—not just the assets—from start to finish get connected to provide an end-to-end view of every step in the workflow. Staying ahead of the curve, Neewee successfully innovated the Process Digital Twin for integrating data by mapping different processes in the manufacturing value chain. A digital twin is created for five different dimensions of the interacting parameters—process parameters, product parameters, asset, work centre, and external factors. Then each gets connected, from upstream to downstream activities, supply chain, etc., to simulate the overall outcome. 

The Value Manufacturers Can Expect from a Digital Twin Service Provider 

The digital twin is an Artificial Intelligence (AI) technology used for data-driven simulation and testing of various scenarios before publishing the actual production plan. It helps manufacturers monitor batches and make decisions about optimum utilization of their resources and the efficiency of their processes. They can also be used for training purposes, where employees can learn how to handle process variations and even predict problems before occurrence in reality.

By aligning digital twin AI solutions to your organization’s needs, you can tackle a host of business challenges: 

  1. Integrated data analytics can power the digital twin to identify important parameters influencing the process workflows or smooth functioning of an asset fleet. It simplifies the analysis of the root cause for variations. 
  2. The digital twin can detect the risk of accidents and predict unplanned asset downtime. Thus, it helps prevent bottlenecks and pile-up of WIP.  
  3. Real-time simulation of production processes provides end-to-end visibility to the planners across the organization and improves process control.   
  4. The digital twin allows the integration of legacy factory equipment into a digital environment. Thereby facilitating the collection of data that would otherwise have gone non-measured. That is useful in meeting the increasing need for adopting Lean manufacturing methods in Industry 4.0.
  5. Digital twin data can enable the production team to gain insights and make timely decisions for process correction and ensure quality at the same time. Saving the manufacturer lot of time and money that could be wasted in trial and error. 
  6. Product Prototyping and Quality Control Management are two massive manufacturing challenges that the digital twin helps overcome.
  7. A digital twin operator will not only provide tools for customers to build digital twins, but it also runs, analyses, and optimizes the digital twin for the customer. 

According to the Forrester report, you can improve operational effectiveness by engaging the services of a digital twin operator. With the help of a digital twin service provider, tech execs can derive the following benefits [2]:

  • Realize returns on digital twin investment more quickly.
  • Get to focus more on your business requirements and less on the undifferentiated heavy lifting or maintenance of the digital twin.
  • Extract insight from both IT and operational technology (OT) data silos.

The concept of the digital twin was first published in David Gelernter’s book ‘Mirror Worlds’ in 1991. Michael Grieves of the Florida Institute of Technology went forth and introduced the concept to the manufacturing industry in 2002. However, NASA used it first to create digital simulations of space capsules and craft for testing. Finally, in a 2010 Roadmap Report, John Vickers of NASA gave the concept its name. [3] And there’s been no looking back ever since! 

Digital Twin market size exceeded USD 5 billion in 2020 and is expected to grow at a 35% CAGR between 2021 and 2027. Increasing adoption of IoT, big data analytics, and the advent of AI/Machine Learning technologies in manufacturing sectors ranging from Automobile and Aerospace to Pharmaceutical & Healthcare are likely to fuel the industry’s growth. [4]

With the advent of AI, rolling out the digital twin is a proud pleasure for a digital twin service provider like Neewee and a joy to experience for the manufacturer. 

As always, feel free to contact us and schedule a demo’ now!

References:

[1] and [2] Miller, P., Matzke, P., Kortenska, E., & Barton, J. (2022, February 17). Now Tech: Digital Twin Service Providers, Q1 2022. Forrester. https://www.forrester.com/report/now-tech-digital-twin-service-providers-q1-2022/RES177089

[3] TWI. (n.d.). What is Digital Twin Technology and How Does it Work? Www.twi-Global.com. Retrieved February 24, 2022, from https://www.twi-global.com/technical-knowledge/faqs/what-is-digital-twin#WhatChallengeshasitSolved

[4] Digital Twin Market Size, Growth Forecast Report 2027. (2021, July). Global Market Insights Inc. https://www.gminsights.com/industry-analysis/digital-twin-market