133 VIEWPOINT INDUSTRIALS & MANUFACTURING Building the factory of the future Digital twins are transforming manufacturing processes and optimising operations Digital twins are central to the factory of the future and are already transforming how manufacturers design, build, maintain and decommission operations. Rockwell Automation and Microsoft are at the forefront, helping manufacturers deploy digital twins to automate production, create resilient supply chains, empower workers, drive sustainability and accelerate business transformation. As digital representations of physical systems, digital twins allow users to visualise and analyse every aspect of manufacturing processes. They are essential to smart manufacturing, with 97 per cent of participants in the 2023 Rockwell State of Smart Manufacturing Report planning to incorporate these technologies. Manufacturers often struggle with vast, siloed data. Digital twins address this by combining and contextualising data across environments, creating virtual models that reveal system interactions at both micro and macro levels. Serving as a blueprint and a single source of truth across the value chain, digital twins enable real-time and historical data analysis. They help users understand why one production line is more efficient than another or how temperature changes affect quality. This digital feedback loop unlocks data value, optimising manufacturing processes, improving safety and reducing commissioning times. Digital twins gain even more power when integrated with cloud platforms like Microsoft Azure. Cloud scalability allows developers to deliver new functionalities across the enterprise, enabling teams to collaborate in real time, regardless of location. Rockwell Automation’s experience demonstrates the impact of digital twins. When relocating a manufacturing line from Switzerland to Milwaukee, digital twins facilitated early design, real-time collaboration and efficient decision-making. They also simulated control systems for equipment retrofits, enabling engineers to validate programmable logic controller code and train operators before implementation. This approach reduced commissioning times, predicted design issues, spotted anomalies and enhanced predictive maintenance, leading to safer and more efficient operations. Digital twins are dynamic tools that address the challenges manufacturers face, fostering growth, innovation and improved operations by providing an enterprise-wide view of data. Rockwell Automation and Microsoft bring deep expertise to support organisations pursuing factory-of-the-future technology, with digital accelerators bridging the gap between business needs and enterprise scaling. Learn more about transforming the factory floor with digital twins at: bit.ly/3Mn8YoE Andrew Ellis is vice president of global portfolio engineering at Rockwell Automation ANDREW ELLIS: ROCKWELL AUTOMATION “Digital twins allow users to visualise every aspect of manufacturing”
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