Digital Twins: Beyond Buzzwords — How They’re Reshaping Automotive & Manufacturing in India

Remember how companies used to design any mechanical product in 1970s and before. Lots of manual calculations on loads, stress, strains etc. Actual drafting boards and prototypes and destructive testing to check durability and reliability. With the advent of computational methods and computers companies started shifting towards Computer Aided Engineering. The benefits: lesser prototyping efforts, lesser physical destruction conserving resources, reduced development time, new types of skills! It was revolution at that time.

So, what’s the future and how allied technologies are helping it. We are seeing GPU’s, super-fast computing on hand held devices, laptops, Big Data and data driven models combined with human intelligence as the trends of the upcoming decade

Digital Twins is becoming a buzzword. However, it is soon becoming a reality! The real story starts when you ask: What business problem are we solving? How will it revolutionize the Business Environment?

It is transforming all operations by enhancing efficiency, speed and smart decision-making.

By definition, a Digital Twin is a virtual replica of a physical product, process or system that continuously replicates real-world data.

Why is Digital Twin emerging as a go-to technology in business and the manufacturing sector?

• Reduce the cost of physical prototypes and associated time. It represents and models the entire lifecycle of a product or process in real time.
• Products, processes, machines and even entire plants can be simulated and optimized virtually without investing in physical setup.
• Enhanced predictive maintenance and reduced downtime: With the help of the virtual modelling manufacturers can anticipate failures earlier and minimize expensive disruptions.
• Supply chain visibility and design-to-delivery alignment: Since every stage of production can be viewed, it leads to better testing, enhanced process optimization and effective coordination from design to supply chain delivery.

From my previous experience in working in companies who utilized the power of CAE and used human interpretations to redesign the products have went building great and better products. They could scale their companies in every aspect. Same is likely to happen as we start adopting this new frontier.

However, any change or new adoption succeeds when leaders view not just as a tech upgrade but as a maximizer for businesses. It is a system-level shift that demands integration into processes, ne skills and culture, not just approaching it as a one-off tool.

The companies using Digital Twins to their full potential aren’t just chasing technology. They are focused on real-time outcomes and measurable results.

How is your organization approaching this shift?

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