Running Head: DIGITAL TWIN 1

DIGITAL TWIN

Atul Bhuju (167013)

Anish Shrestha (167089)

Sadikshya Shrestha (167097)

BBA Semester V

Section A

KATHMANDU UNIVERSITY SCHOOL OF MANAGEMENT

Bachelor of Business Administration (BBA-Honors /Emphasis)

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ABSTRACT
Digital twin refers to a digital replica of physical assets, processes, people, places, systems and
devices that can be used for various purposes. A digital twin works through edge processing that
involves use of sensors/radars that consistently collect and synthesize data from various sources
which is incorporated with AI algorithms is integrated into a physics-based virtual model and
then resulting analytics is applied into these models, making it a live model of the physical
equipment. Digital twin, being one of the most innovative developments in the field of
technology at present, has a wide area of application that brings many benefits along its use and
integration into company practices. However, it has its own sets of challenges and difficulties in
implementation. These aspects of the technology form the basis of this paper. The objective of
this paper is to discuss some major progresses achieved in digital twin technology, its advantages
and challenges, get insights into performance of some organizations using the technology and the
possibilities of future advancement.

Keywords: digital twin, replica, virtual, edge processing, predictive, AI algorithms,

integrate, insights, analytics, real-time, simulation, sensors, paradigm
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INTRODUCTION
A digital twin refers to the virtual model of a process, product or service that data
scientists and IT experts can use to check how the device will operate before the actual devices
are built and deployed. It is the replica of the physical devices in the virtual world. It acts as a
bridge between the physical and the digital world. This pairing of the virtual and physical worlds
allows the analysis of data and monitoring of systems to cure the problems before they even
occur, develop new opportunities and plan for the future by the use of simulations only. When a
new product idea is introduced it is better to form a digital twin to check how the product will
work in the real world. This not only helps to check whether the idea becomes successful or not
but also helps to rectify the error if any occurs.

According to Kaiser, SAP Senior VP of IoT, 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. The companies that fail to grab the opportunity will be left
behind. According to Skerrett VP of Eclipse Foundation, a digital twin is simply a virtual
representation of a physical asset.

Digital twin is one among the top 10 strategic technology trends named by Gartner Inc. in
2017. Digital twin can be taken as the ability to take the virtual representation of the elements
and the dynamics of how an internet of things device operates and works. It is more than just a
blueprint which helps in understanding all of its dynamics like whether an electron moves or the
device that’s moving itself.

The concept of the Digital Twin can be taken back to a presentation to industry in 2002
for the formation of a Product Lifecycle Management (PLM) center presented in University of
Michigan. The presentation was originated by Dr. Grieves and was called “Conceptual Ideal for
PLM.” The presented model had all the elements of the Digital Twin i.e. real space, virtual
space, the link for data flow from real system to virtual system along with the link for
information flow from virtual space to real space.

The rule driving the model was that every framework comprised of two frameworks, the
physical system and the virtual system. The physical system was the one that has dependably
existed while the new virtual system was the one that contained the majority of the data about the
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physical system. This implied there was a reflecting or twinning of systems between what
existed in real space to what existed in virtual space and the other way around. The PLM or
Product Lifecycle Management in the title implied this was not a static depiction, but rather that
the two systems would be connected all through the whole lifecycle of the system.

The reference to PLM demonstrated that this applied model was and is proposed to be a
dynamic model that progresses over the lifecycle of the system. The system develops practically
toward the start of its lifecycle, takes physical shape in the generation stage, proceeds through its
operational life, and is in the long run resigned and discarded.

Digital twins are made in a similar CAD (computer aided design) and demonstrating
programming that experts and specialists use in the beginning times of product improvement.
The advanced twin model is held for later phases of the item's lifecycle, for example, review and
support.

How does a Digital Twin work?

Sensors associated with the physical item gather information and send it back to the
advanced twin, the information is than received by the actuator and the virtual system is created
and their connection enhances the item's execution through a support administration.
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REASON WE SELECTED THE TOPIC

Digital twins can not only be used in manufacturing sector but also in sectors of energy,
transportation and construction. With the use of digital twin along with developing simple
structure such as buildings, small products many different, large, complex items such as aircraft
engines, trains, platforms and turbines could be designed and confirmed digitally before being
actually producing it. It gives deeper insights into the products behavior; this feedback helps to
remotely understand the real-world product uses and what customer values most. It affects the
process i.e. the design, build and operate phases.

Digital twin allows companies to identify risks as well as make better judgments about
what will happen in the future. This insight not only helps in operational efficiency but also helps
to analyze regarding how companies can best allocate the money to invest in different products
to improve their environment.

This has been an emerging issue in the IT field as it enables companies to move beyond
the potential and actually apply the analytic and transformational insights of AI to improve the
bottom line. We selected this topic as we wanted to learn what digital twin is, how can it be used
in the market to bring efficiency in our products and what prospect it brings in the future for
further effectiveness in the organization.
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MAJOR MILESTONES IN THE DEVELOPMENT OF DIGITAL TWIN

The notion of the Digital Twin dates back to a presentation from University of Michigan
to an industry, in 2002 for the formation of a Product Lifecycle Management (PLM) center. At
the time this concept was introduced, it was relatively new and immature idea. In addition, the
information being collected about the physical product was limited, manually collected, and
mostly paper-based.

Digital Twin Concept Model

Concept Model of Digital Twin (Figure 1)

It contains three main parts:

a) Physical products in Real Space,

b) Virtual products in Virtual Space, and
c) The connections of data and information which ties the virtual and real products

In the decade since this model was introduced, there have been tremendous increases in
the amount, richness, and fidelity of information of the both physical and virtual products. Not
only the amount of information we have available has improved, but also numerous behavioral
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characteristics have been added so that visualization of the product along with running test on it
for performance capabilities can be possible.

We have the ability to create lightweight versions of the virtual model by selecting only
the required attributes that we require without carrying around unnecessary details. This has
reduced the size of the models, allows for faster processing, reduced time and cost of
communicating and also can be shared not only with the organization but also throughout the
supplier network. This improves both collaboration in reducing time to understand and
enhancing quality and depth of understanding of product information and changes.

The process of information collection has also progressed from being manual and paper
based to being digital and being collected by a wide variety of physical non-destructive sensing
technologies, including gauges and sensors, lasers, vision systems, white light scanning and
Coordinate Measuring Machines.

Despite the progress in this field, there still remain one issue that while the data
information of each of these areas has increased dramatically, the connection between the two
data sources has lagged behind, which is one major challenge in this field.

Currently, researchers are focused on the full end-to-end digital design that provides the
ability to run predictive analytics against assets and close the digital loop across the asset’s
lifecycle. It provides enterprise with the knowledge from feedstock to planning, scheduling,
operations and distribution.
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BENEFITS
The applicability of Digital Twin in different fields such as in agriculture, transportation,
health care and entertainment and for purposes like design, planning, manufacturing, operation,
simulation and forecasting is an advantage of this technology in itself. However, when studying
the subject matter from the perspective of a business report, we can short list some major
advantages as follows:

a. Preparing perfect prototypes before the actual product

A digital twin makes it possible to manufacture extremely high-quality products as
construction of expensive prototypes is replaced by a manufacturing process guided by a virtual
template. The virtual model of possibly anything can be tested and optimized. This extensive
process guarantees the production of a sophisticated and first-hand product before the production
and manufacturing of an actual physical product.

b. Reduce product defects and cost while enhancing product

Digital twin also supplements the physical product during its entire lifecycle as the built-
in sensors on the physical machine constantly transmit information to the clone. The digital twin
analyzes this information and uses it to continuously improve and enhance the quality of future
products as well as optimize the performance. Along with improvements to the final product,
these sensors allow for the implementation of predictive maintenance. Continuous transmission
of control values to the cloud also makes it possible to detect irregularities quickly and easily. It
would also help in determining when maintenance is necessary based on the frequency of use,
wear and tear. This helps avoid expensive, unnecessary or unexpected repairs, hence, savings of
money and resources.

c. Smarter, data-driven decision making

A digital twin can eliminate the risks involved with decision making due to the data
driven nature of the technology. As it can provide real time information on the object, system or
service, including position, performance and working condition by using and analyzing data
from sensors installed on physical objects, the digital twin acts as an intuitive interface into
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physical spaces and systems, providing real-time information, data contextualization and a better
overview to create actionable comprehensions.

d. Increase collaboration
Creating a digital twin network makes it easy to share data with internal colleagues,
external supply chain partners and even the customers. With access to the same insight as the
business operators, the business house, their partners and customers can collaboratively improve
products, production processes, and more.

Sharing the digital twin data with internal departments in the organization ensures
everyone’s on the same page. Supply chain partners can experience the benefit from the network
of digital twins with enhanced visibility. Finally, digital twin networks help to monitor how
customers interact with goods, remove underused features from future product iterations or
develop new products that highlight popular features and improve the marketing landscape.

e. Better prediction of future scenarios

Virtual clones do not have concept of time and space which is why they are
revolutionizing predictive maintenance. With a single click of the mouse, they can clock
hundreds of operating hours and simulate uncountable environmental conditions. The
information provided to these digital twins by the physical product helps manufacturers gain
more insight into their products and make it possible for them to predict the future
product/production scenario more than they ever could before.
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CHALLENGES
a. Hardware
Hardware is the major bottleneck to a lot of IoT initiatives and digital twin is no
exception. In order to successfully implement a digital twin project, it would require a
significantly extensive no. of sensors, which could be very costly depending on what type of
sensors will be required. In addition, deploying so many sensors is complex, time consuming and
managing them is difficult.

b. Connectivity
Connectivity is another challenge for many digital twin concepts, primarily because
providing connectivity to thousands or millions of physical assets and sensors used in them is
demanding. Situations could be worse if the assets are something that constantly moving parts, or
moving itself, like a turbine, or if the asset is in areas with poor cellular reception or so.
Furthermore, as most IoT architectural patterns currently rely on the edge and processing in the
cloud models, the bandwidth required to gain value from a digital twin scenario that could
potentially be processing billions of data points is incredibly tremendous.

c. Including data from many sources

It is difficult to anticipate the nature of simulation models, data types and data analysis of
the sensor data. Such things might be necessary to support the design, introduction and service
life of the digital twins’ physical counterparts. Though 3D geometry is sufficient to communicate
the digital twin, the geometric model may not be able to perform simulations or analyze data if it
is not enriched with additional information and software support. Including these additional
information and software data and managing these sources such that they can be converted into a
common, easily accessible template demands high technical resources and skills.

d. Security is a threat
Digital twin is an exact replica of any physical entity with every bit of information and
data about it since the time it has been integrated with software and sensors required to make the
digital copy of the entity. Along with that, the technology requires best-in-class modeling
practices to increase transparency on complex digital twin designs so that it becomes easier for
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multiple digital twin users to collaboratively construct and modify digital twins, in order to
minimize the amount of effort to enable changes within the digital twin or between the digital
twin and external. Hence, if the system that operates and manages the digital twin breaks down,
all the unities connected to it cannot function, or if it is hacked, the hacker gains all facts and
records of the entity.

ORGANIZATION USING DIGITAL TWINS

The benefits of creating digital replica of real-life objects, processes and system, known
as digital twins, by attaching Internet of Things (IoT) sensors to them are endless. Digital twin
technology has implications across a wide variety of industries: agriculture, manufacturing,
energy, transportation and construction. Mainly, digital twins enable organizations to see how
goods and devices perform and lives throughout its life cycle in real time. This in-the-moment
data allows companies to improve processes, increase efficiency, and create new business plans
and models.

The rising demand of digital twins in IoT projects today de facto is chiefly stated in the
scope of the manufacturing sector, through connecting digital and physical worlds in current
trend of Industry 4.0, the virtual transformation of industrial and manufacturing markets overall,
including smart supply chain and logistics management. Producing and delivering high quality
products on time to anxious customers is critical for any creator, and if their machines are not
working in unity and at their apt capacity, it can impact the production, deliverability, employees
and, finally, customer satisfaction with the company. By allowing manufacturers to check
performance in real time to inform working process and test efficiency updates without
interrupting standard workflows errors, manufacturers get smarter and more informed with
digital twin by projecting loads of data points collected throughout their facilities.

1. NASA
NASA was the first to dabble with digital twin as far back as the early days of space
exploration after NASA’s Apollo 13 mission encountered disaster. NASA applies digital twins to
aerospace machines: essentially flying both in the digital and real world simultaneously. In the
last 15 years, the digital revolution has made this concept extremely versatile and powerful.
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NASA uses digital twins today to make recommendations, develop their roadmaps and develop
next-generation vehicles and aircraft technology.

To address the shortcomings of conventional approaches, the model of a Digital Twin

was presented. The digital twin is an integrated multi-physics, multi-scale, probabilistic
simulation of an as - built vehicle or system that uses the best available physical models, sensor
updates, fleet history, etc., to mirror the components of its corresponding flying twin. The digital
twin is ultra-realistic vision to create, test and build the equipment in a virtual environment and
physically build to match to its digital twin through sensors. The digital twin integrates sensor
data from the vehicle’s on-board IVHM system, maintenance history and all available historical
and fleet data. By combining this information, the digital twin continuously forecasts the health
of the vehicle or system, the remaining useful life and the probability of mission success. The
systems on board the digital twin is also capable of mitigating damage or degradation by
activating self-healing mechanisms or by recommending changes in mission profile to decrease
loadings thereby increasing both the life span and the probability of mission success.

2. Kaeser Kompressors
Germany’s Kaeser Kompressoren, the global air compressor manufacturer that sells air-
as-a-service is but one example of how manufacturers are grasping a notion of digital twin with
predictive analytics tools and Industrial Internet of Things (IIOT) to improve product quality,
explore new business models, optimize operations and strengthen customer relationships. By
scrutinizing the continuous data supplied by sensors, Kaeser develop predictive maintenance
programs and packages around that product that can pinpoint issues that allow them to improve a
product and visualize how a product is operating and changing in the real time.

For instance, Smart sensors are placed on agricultural equipment that allow farmers to
optimize fuel consumption, prevent downtime and cut fertilizer use. Kaeser, a company that
produces vacuum products and compressed air has created a digital twin network compressor
using Aucotec’s Software Engineering Base (EB) that provides valuable insight into product
design, to monitor performance of devices and equipment in the field and measure customer air
consumption in real time, enabling the company to make design changes that hopefully result in
fewer failures and predict pressure, temperature or level sensors and the units being used for
customer ease. Instead of equipping devices at a customer’s place and leaving operation to them,
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Kaeser keeps the asset throughout its lifecycle and charges fees based on air consumption rather
than a fixed rate. With the continuous supply of real-time asset data, Kaeser ensure equipment
uptime and maintenance more efficiently. To date, by using digital twins, the company has cut
commodity costs by 30% and on boarded 50% of major vendors.

And with General Electric’s digital wind farm project centered on performance
optimization and sensor data processing, this method reportedly helps wind farm companies
increase energy production by up to 20% and generate extra $100 million in revenue over a
turbine’s lifetime.

LESSON OF ITS USE

• With digital twin, engineers gain insights in the real-time use of the products they make
and designed with all the benefit that brings.
• As digital twins are linked with their real-time physical twin, the list of use benefits and
cases continues: new ways innovating products come into reach and the face of services
changes, products can be improved, consumer insights and customer behavior data and
preferences can be gathered, new products can be developed in a more customer- and
data-driven way.
• The advanced ways of assets and product management and maintenance come within
reach with real-time capabilities as there is a digital twin.
• In a complex environment, decisions can be taken with ease as is already the case in, for
instance, wind turbines whereby digital twin controls virtually every aspect of the full
environment and enables reduced fuel consumption, optimized processes, and thus realize
abundant benefits from its use.
• Linking digital twins to its physical twins with continuous supply of data, however, can
require additional skill sets such as expertise in artificial intelligence, predictive analytics,
machine learning, internet of things and other data-science capabilities. Digital twins can
unnecessarily increase complexity concerning about cost, security, privacy, and
integration.
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FUTURE TRENDS AND/ OR DEVELOPMENTS

With the immense technology push in the cloud solutions, sensors, and Internet of Things
(IoT), the potential of digital twins is no longer just an idea, but a disruptive power of innovation,
and will radically change business models. The digital twin, in combination with IoT sensors and
other emerging technologies, is now incoming a new stage in market acceptance. After years of
estimating, it becomes increasingly essential component of life. According to several research,
IoT will reach the height of productivity between 2019 and 2022, followed by digital twins from
2022 onwards.

The future will change toward the digital replica of environments and factories, as well as
processes and personnel which along with digital twins of physical assets will allow a
progressively detailed presentation of the real world for analysis, simulation, and control to
recreate catastrophes virtually to obtain significant improvements in cycle times and costs.

For example, Philips with digital twins can revolutionize both hospital operations and the
care provided to patients. They have been testing making digital twins of humans and organs so
they can be fully studied, and procedures can be simulated and tested prior to being done on the
actual person. This has the potential to improve patient outcomes and decrease mortality rates.

Similarly, it is predicted that by 2020 there will be 10 million self-driving cars on the
road. Tesla is applying digital twin to its cars. Every car report back on a daily bases and those
data are used by simulation programs on the digital twin to discover possible glitches and
provide corrective actions. Much of the sensor infrastructure will be already in place in newly
released vehicles that will analyze the data and perform predictive analysis that will help make
driving experiences smarter and safer for car owners.

Digital twins will touch every area of our lives: things, services, people, and networks
and will change how businesses create, simulate, perform, predict, and self-heal.
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CONCLUSION
Technology and innovation are taking major strides on a regular basis. Newer and
updated technologies are coming up in the market day by day. Entrepreneurs and companies are
focusing extensively on innovation in order to expand and sustain their operations. The world
has come a long way in this field and what would have been difficult to imagine ten years ago
has become a reality now. Organizations are using the technologies to increase its productivity
likewise excel in providing the best quality and increase the customer value. Digital twin is the
best tool they can use to achieve competitive advantage in any field. It gives helpful bits of
knowledge by making a virtual space where information can be imagined. With the digital twin
model, we can view the ideal characteristics, our actual trend line to determine for range of
products whether we are where we want to be.

Despite the fact that digital twins help the organization to progress and bring provide
competitive advantage to the organization, the process of digital twin can be difficult to
understand and requires skilled human resources such as engineers to develop this system. Due
to this many organization may not be able to innovate using the digital twin system or even
develop it. However, the investment if made by the organizations can pay off in the long run.
The internet has made it somewhat cost-effective than when it was first introduced. Companies
should and are learning that digital twin technology has proved to be successful and would enjoy
a competitive advantage if they adopt it.

Digital twin is a technology among the top strategic technology in the present market. It
is part of a new industrial revolution which has unlimited possibilities. The way it combines the
virtual world with the real world can have applications that people could only dream about. This
can take machine autonomy to the next level especially with the rapid growth in artificial
intelligence. There is no telling the heights that this concept can reach in the near future and
organizations should definitely invest in applying digital twin in their products. The future of
technology is full of excitement and businesses should choose to keep a close eye on such
innovations to get a first-mover advantage.
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