The digital twins have consolidated as one of the key technologies in the digital transformation towards industry 5.0. Their flexibility, scalability, and ability to adapt to multiple sectors and sizes (from SMEs to large corporations) make them a strategic tool for improving operational efficiency.

A digital twin offers the possibility of virtually representing a process, a plant operation, or a physical asset to understand its behavior. As indicated by Deloitte, digital twins allow capturing data on physical and dynamic properties such as thickness, color, hardness, weight, speed, or environmental conditions, to simulate scenarios, predict behaviors, anticipate failures, and optimize decisions with greater accuracy.

The value they bring will depend on the type of process or system being digitized, but among the most significant benefits are: time savings, cost reduction, and increased quality of the products and services offered.

Benefits of Digital Twins

There are several key benefits that digital twins offer to companies:

1- Control of productive status

One of the most immediate advantages is the continuous monitoring of processes. Digital twins have very flexible connections that allow them to connect to almost any data source. They can receive data from online updated Excel files, connections to common SCADA, MES, DCS, ERP systems, IoT sensors, or even direct connections to specific assets via API.

This integration allows for defining key metrics, visualizing them in real-time, and making decisions based on reliable information, always aligned with business objectives.

2- Real-time optimizations and corrections

Constant monitoring allows for detecting inefficiencies or deviations in performance and also acting on them immediately. When a process deviates from its usual performance, the digital twin offers the possibility of adjusting parameters, correcting failures, and stabilizing the system before the impact is significant.

With these tools, you can create plans to optimize operational processes in the industrial sector in the most efficient way for your business.

3- Predictive maintenance and error prevention

One of the most powerful functions of the digital twin is its ability to work with historical data in addition to real-time data. This allows for scheduling predictive maintenance using machine learning algorithms that identify behavior patterns and predict when and where a failure might occur.

For example, in the manufacturing sector, many companies monitor parameters such as vibration or temperature to detect anomalies in hydraulic presses or assembly lines, thus scheduling preventive maintenance accurately. Predictive maintenance also plays a key role in extending the lifespan of assets and reducing unexpected breakdowns, which often cause spikes in consumption and additional resources for emergency repairs.

4- Scenario analysis and simulation

Before launching a new product line, redesigning a process, or implementing an improvement, companies can use the digital twin to simulate different scenarios. This allows them to see how the system would react to certain configurations or decisions without having to invest or take real risks.

It is a key tool for product development, plant planning, and validating changes before their application in the physical environment.

5- Cost reduction and increased ROI:

Although digital twins require an initial investment, their return is rapid and measurable. As explained by McKinsey, they enable better and faster decision-making and achieve a greater return on investment (ROI) thanks to their simple, data-focused interfaces.

Digital twins help to:

Reduce downtime. Minimize errors and reworks through simulations. Optimize resources and materials by reducing waste. Improve investment planning based on real data.

6- Scalability and flexibility:

Some digital twin platforms allow companies to scale projects modularly. They are easy to integrate, and one can start with the digitization of a specific machine or process and, if the results are satisfactory, progressively scale to the entire plant or even to facilities in different locations. This approach to scaling ensures that each stage of growth brings real value.

7- Multi-plant management:

The digital twin can integrate data from multiple sites in a unified environment and display it through an interactive map. Through this map, the different facilities are visualized in their respective locations, along with their performance indicators, making it easier to compare the performance of each. Additionally, from this global view, users can access each facility to navigate its 3D environment and consult more specific data for each one.

8- Regulatory compliance:

The total traceability and control of critical parameters that these advanced technologies offer allow companies to comply with internal and external regulations more easily. Additionally, intelligent alerts can be configured to notify responsible parties if a value falls outside acceptable ranges, and if necessary, remotely stop assets thanks to bidirectional connectivity.

9- Sustainability and reduction of environmental footprint:

The incorporation of digital twins is one of the most effective ways to move towards a more sustainable and environmentally responsible industry. By monitoring energy consumption, the use of raw materials, and waste generation, companies can identify, quantify, and address inefficiencies where they are truly needed.

Moreover, they allow for detecting patterns of overconsumption, leaks, or anomalous spikes in resource usage, to implement corrective actions immediately and avoid waste of materials or the emission of pollutants such as CO2.

10- Better data-driven decision-making:

Thanks to its flexibility to connect with various data sources, such as financial systems, industrial sensors, or management tools, the digital twin allows for a holistic view of the business's status.

This facilitates the creation of customized KPIs through formulas and visualizing updated results in real-time through interactive dashboards or immersive 3D environments.

By presenting information clearly, visually, and up-to-date, its interpretation by different profiles, such as technical teams or executive committees, is improved, resulting in a more agile decision-making process aligned with objectives.

A real competitive advantage

Companies that adopt digital twins gain in agility, efficiency, control, and are better prepared to face the challenges of today's market.

At IMMERSIA we have supported clients from sectors such as manufacturing, energy, construction, or smart cities. Each with a different starting point, but all with a common need: to optimize their processes and visualize their data more efficiently to make better decisions.

For more details on the challenges they faced before implementing TOKII and the results they achieved, feel free to visit our Success Cases.

Do you want to know how you could apply digital twins in your company?

If you also want to start transforming your operations through advanced data visualization, predictive maintenance, or simulation of complex scenarios, contact us and our experts will show you how you can transform your business with our TOKII Digital Twins Platform.