In today's fast-paced manufacturing and logistics industries, every decision matters. Companies face labour shortages, rising costs, and increasingly complex production processes while striving to optimise resources and maintain a competitive edge. The pressure to innovate is higher than ever.
So, how can businesses ensure continuous production while making smarter, data-driven decisions?
The answer lies in Digital Twins—virtual replicas of real-world operations providing critical insights and driving efficiency.
During our recent TX Webinar on simulation and Digital Twins, we explored how a well-planned Digital Twin implementation helps businesses prevent costly mistakes, optimise resources, and achieve substantial cost savings. The return on investment (ROI) is clear—businesses that leverage Digital Twins make better decisions and stay ahead of the competition.
Many companies today face critical operational challenges:
These decisions revolve around two key objectives: boosting efficiency and making smarter investment decisions.
Without the right insights, businesses risk costly missteps, such as purchasing unnecessary equipment, inefficiently utilising space, or implementing automation that fails to deliver ROI.
This is where Digital Twins make all the difference.
A Digital Twin is a real-time, virtual replica of a factory, production line, or warehouse. Unlike static models, Digital Twins allow businesses to simulate, test, and refine processes before implementing real-world changes—minimising risk and maximising returns.
For example:
The ability to experiment virtually before committing to real-world investments is a game-changer.
One of the most compelling real-world examples of Digital Twin success we discussed in our previous webinar was Mr. Mallo, Europe's largest marshmallow manufacturer.
Following the closure of one of its production sites, Mr Mallo needed to increase production at another facility by 70%—without overwhelming operations or making premature capital investments.
The company built a Digital Twin of its entire production process. This virtual model allowed them to:
Image of Mr Mallo's Digital Twin Production Factory
By leveraging this technology, Mr. Mallo not only transformed its production process and avoided unnecessary costs but also turned the model into a continuous improvement asset for daily operations.
Mr. Mallo’s success is just one example of how Digital Twins drive efficiency and cost savings. Want to see how another industry leader transformed operations? Read the Oerlikon Eldim case study here.
Mr. Mallo's case isn't unique—more and more companies in manufacturing and logistics are using Digital Twins to navigate complex operational challenges.
Where businesses once relied on experience and assumptions, they now use data-driven simulations to predict the impact of investments, operational changes, and automation initiatives precisely.
By implementing tools such as Siemens Tecnomatix Plant Simulation, companies can:
Whether you're a manufacturer looking to expand capacity or a logistics provider aiming to optimise warehouse space, a Digital Twin provides the visibility needed to make the right choices.
Digital Twins are revolutionising the way factories operate. Learn how businesses are shifting from static blueprints to dynamic digital factories in our blog: Transforming from Static Blueprints to a Dynamic Digital Factory.
Did you miss our TX Webinar on simulation and Digital Twins? Want to see how this technology can transform your operations?
Contact us today for a consultation or live demo—and discover how Digital Twins can drive efficiency, cost savings, and smarter decision-making in your business..