Hello learners, welcome to the topic on digital thread and
digital twin in manufacturing.
At the end of this topic,
you will be able to explain digital thread in manufacturing.
Explain the benefits of digital thread, define digital twin,
identify the digital twin technology used in manufacturing operations.
So first, what is digital thread?
The digital thread refers to the communication framework that enables
a connected flow of data and an integrated view of asset data throughout
its lifecycle, in terms of traditional siloed functionality.
The concept of digital threads raises the bar on providing
the right information at the right time and in the right place.
The concept of digital threads was driven by the USA Military Aircraft Industry and
the desire to improve the performance of future programs by using digital
technology to apply lesson learned to current and upcoming programs.
However, this concept and technologies are attracting attention beyond the aerospace
and defense industries, converging with the digital manufacturing and
cyber-physical system goals of industry 4.0 and smart manufacturing.
Digital threads creates a closed loop between the digital and physical worlds,
transforming how the way of the product are designed, manufactured, and serviced.
Digital thread seeks to provide easy, universal access to data.
They track a single relevant data set tailored to the business process and
the capabilities to ensure continuity and accessibility.
Digital thread provides a framework for communication.
Digital Thread provides a formal framework for
controlled intersection of relevant technical and built data to access,
integrate, transform, and analyze data from heterogeneous
system throughout the product lifecycle for practical use.
It is necessary to provide the functionality to make information.
Digital threads under twin include design time requirement,
validation and inspection records, built-time data,
flow-time data, and maintenance-time data.
Now let us look at an example for manufacturing.
The physical world is vast, there are physical products that
companies create their components, parts, equipment, and assets.
There are sensors and infrastructure that surround these physical things and
there are people who interact with all of them.
In most cases, they look different.
It is difficult to determine where and how they intersect and are interrelated.
This can be useful for digital and related to digital threads.
Next, let us discuss the five key components of powerful digital thread in
manufacturing.
Digital threads can deliver value by enabling automation,
extending business process between the department, and
providing updated business data for making informed decision.
Manufacturers should consider five important things when they building
an effective digital thread.
Now let us look at each one in detail.
First, connect the stakeholders to increase profitability and productivity.
Create a single source that pulls data from different sources and
then uses that data to connect performance and
manufacturing information between the digital twin and downstream application.
That is design, engineering, sourcing, manufacturing partners, etc.
Removing departmental silos enables product teams,
cost of engineering, and sourcing colleagues to design and
validate their product simultaneously with collaboration to
ensure that they are manufacturable, meet the target cost and production deadlines.
The next component is to simplify and accelerate the process automation.
Automation plays an essential role in the increasing efficiency and
decreasing operational complexity.
Automated tools can help you incorporate design for manufacturing,
that is, DFM and manufacturing cost analysis into your design process.
Use rules, roles, and trigger to encourage groups and
teams to act and generate high level stakeholder reports.
Identify components for redesign or
re-provisioning that have significant cost impact.
Identify outliers with manufacturability issues.
Inform stakeholders for high risk part design for immediate review.
The next component is to improve the plans with accurate data and
fact-based insights.
Strategic planning requires the ability to gather information,
including robust product data, details on manufacturing cost.
Executives can analyze this data using different scenarios,
such as access the potential for
using alternative material to avoid supply chain delays.
Investigate how different manufacturing processes affects the production cost and
availability.
Perform matrix calculation to compare difference in regional
manufacturing cost by the workforce, materials, overhead,
equipment or fixed asset ratio, and rate of return.
Consider other what if scenarios to plan potential market changes.
Moving on to the next component, that is,
optimize manufacturing using digital factory simulation.
It's crucial to have access to the latest information because of
dynamic fluctuation in the prices of raw materials,
local manufacturing costs, and supply chain disruptions.
Since the ERP system contain historical pricing information,
they provide only indicator insights.
Procurement teams can identify cost saving and meet production goals,
with updated materials and manufacturing pricing.
Optimal digital representation of physical factories include
regional data library provides extensive data collection for
calculating manufacturing cost and
executing production scenarios in multiple regions.
Manufacturing cost model study alternative production
to save cost by simulating the cost model in minutes.
And the next component is improve supply chain speed, flexibility, and agility.
Manufacturers can accelerate procurement through collaboration search engines and
understand the detailed manufacturing costs and capabilities of their suppliers.
Digital factory also help streamline the estimation process itself.
For established manufacturer supply relationships,
the sourcing model can redefine to support the zero request for quotation process.
In this process, the manufacturer orders the design without waiting for a quote.
Next, let us discuss the benefits of digital threads.
For industrial companies, the benefits of digital thread
can be divided into five main categories and
realized across the product, people, processes, and location.
Now, let us look at each categories in detail.
First, let us look at the technical excellence improve quality and
initial yield.
Reduce rework, scrap, site downtime, and warranty cost.
Reduce time to new product development and market launch.
Second, manufacturing efficiency improve overall equipment effectiveness and
production efficiency.
Reduce plant downtime and switch over time.
iImprove overall throughput and employee productivity.
Next product and service innovation increase customer retention and
satisfaction.
Product as a service and result based business model impact revenue.
Next service optimization,
improve technician effectiveness and initial action rate.
Reduce asset downtime, track roles, and resolve issues faster.
And the next benefit is sales and marketing experience,
increase opportunities for net promoter scores, upsells and cross-sells.
Improve customer product usage and training