AW: Can you cite an example of how integrators and OEMs are using digital twins in the commissioning stages of a new or existing plant?
Sarvo: RidgeTech Automation Inc. was recently involved in the design, build and commissioning of multiple material handling systems for two 100,000 square foot vertical farms located in North America. The equipment included automatic storage and retrieval systems (ASRS) and a host of conveyance that moved product through the process from seed to harvest.
The ASRS units were large and heavy, standing over 40-ft. tall and they left no room for error, even during initial startup. Using Emulate3D, RidgeTech was able to virtually commission the systems ahead of the factory startup to prove out the logic and minimize the chance of damage to equipment during the first phases of testing. Having the operator interface running alongside the digital twin application allowed us to address real-life client concerns before the equipment was shipped to site. This process shortened the initial commissioning window and helped reduce delivery time for the complete solution.
AW: What about using digital twins to test changes/improvements to existing equipment operations? Can you provide an example of that?
Sarvo: GA Pet Food Partners engaged in a project with the goals of increasing capacity, flexibility and traceability, while driving down costs, errors and the need for manual intervention in their processes. The original manufacturing process had little automation and their manufacturing execution system (MES) also relied largely on manual interactions. To achieve their goals, GA Pet Food Partners used Emulate3D software to produce a digital twin of their new automation designs and integrated the digital twin with their MES system, allowing them to test, tune and optimize the MES system with all the newly available automation. In addition to achieving their production goals, GA Pet Food Partners noted the project would have taken three to four months longer to complete without this technology.
AW: The pros of digital twins, such as reduced downtimes and predictive maintenance, are often promoted. But what about the downsides to using digital twins for commissioning and/or testing a new or upgraded process?
Sarvo: When it comes to digital twins, there can be a risk to return on investment when engineers go too deep down the rabbit hole. Sometimes people think they want a digital twin of everything without really understanding why. If we seek to build a digital twin in excess of its real purpose, it could become overly complex, require much greater engineering effort and possibly still not provide the insights needed.
Cultivating a workforce with the right skill set is another challenge we see with digital twins. When an organization begins its digital transformation journey, leaders often get caught up in the cost of software tools, but really, the cost of the software is insignificant when you find or grow engineers with the talent to wield it. To be successful, digital twin modeling should not be an occasional part of someone’s work, it should be most of a person’s work. This requires real commitment to change, which can be challenging.