How Digital Twin Modeling Is Used In Manufacturing & Modular Construction

Digital twin modeling is one of the many strategic technology trends growing worldwide because of its many benefits across industries. A digital twin is a virtual replica that mirrors the physical world. Digital twin modeling has countless advantages, but the most notable is that it allows for testing and experimenting without affecting the real thing. 

Using digital twin modeling for manufacturing specifically helps businesses design, map, capture, and structure process variables into a continuously updated database. Then, the database can be accessed and used across the entire business or organization. Some of the specific ways it’s used in manufacturing include: 

Testing new products. Manufacturers can design a product or physical asset in a digital environment and see how it would perform on the assembly line before building a physical prototype or the true product.

Predicting maintenance. In the physical factory or facility, manufacturers can use sensors to send data to the digital twin. In doing this, they can predict when equipment might fail and schedule maintenance or repairs proactively.  

Optimizing processes. Experimenting with different production layouts or workflows in the digital twin helps manufacturers identify bottlenecks or potential challenges and make changes, resulting in a more improved and efficient process. 

Training employees. New employees or trainees can practice key tasks in the digital twin before working on real equipment, highlighting questions or concerns before hitting the factory floor. This reduces the risk of accidents and distractions during real-time production. 

Like countless other industries, digital twin modeling is revolutionizing the construction industry, especially in modular construction. By creating a digital representation of a modular building, project teams can simulate various scenarios, identify potential issues early, and optimize the entire process.

For example, in traditional construction, if changes are made to the building or structure during installment, the last-minute adjustment may not get back to the designer. When this happens, you run the risk of unforeseen design issues popping up in the future. 

On the other hand, with modular construction, designing and manufacturing happen in the same facility. This means, that if an issue comes up during the manufacturing process, workers can tell engineers a change needs to be made immediately, and then add the update on the digital twin. 

Integrating digital twin models provides a powerful tool for improving the efficiency, quality, and sustainability of modular construction projects. By creating a virtual representation of the building and floorplans, project teams can make informed decisions, reduce risks, and deliver projects on time and within budget. Continue reading to see some ways digital twin modeling is used in modular construction.

Process optimization and quality control are two essential components of manufacturing processes. By stimulating manufacturing processes, we identify potential problems and improve efficiency. 

Additionally, we ensure modules are built to the exact specifications before they’re transported to the site, saving time and money that’s often wasted on mistakes and changes. 

Route planning and site logistics are both positively influenced by the revolution of digital twin modeling. Simulating transportation routes helps find the most efficient way to get your modular building to the construction site in a timely and cost-effective manner. 

Furthermore, when using digital twin modeling to plan the placement of the modular building on your site we consider factors like crane access and utilities beforehand, ensuring the installation process runs smoothly. 

Modular construction is known for its sustainability. Integrating digital twin models allows manufacturers and designers to analyze energy consumption patterns and find opportunities for improvement, making it more energy efficient. Sensor data from digital twins also predicts equipment failures and can schedule maintenance or repairs proactively. 

Digital twin modeling includes more than just visualizing the building itself. You can also simulate different scenarios and virtual environments, such as natural disasters or construction accidents, to assess risks and develop mitigation strategies. In the same respect, integrating digital twin models helps identify potential safety hazards and implement measures to prevent accidents. 

Integrating digital twin models into the modular construction process offers many advantages, including: 

• Improved efficiency and productivity
• Enhanced quality and safety
• Reduced costs
• Improved decision making
• Enhanced sustainability

Every modular building needs to fit unique clients’ needs, and digital twin modeling plays a key role in how we do that. By integrating digital twin models, it’s possible to present accurate, visual representations of what the building will look like before manufacturing even begins. 

This allows modular building providers to meet any specifications or requirements as well as get approval on the space.