January 05, 2024
The convergence of IT (Information Technology) and OT (Operational Technology) is reshaping how manufacturing companies operate. Manufacturing processes are growing more complex, while the workforce is evolving at a rapid pace, and many businesses are struggling to identify where to begin their digital transformation journey. Coupled with an aging workforce and a shortage of skilled professionals, the challenge is more pressing than ever. So, how can manufacturing companies successfully adapt to this new era?
For many manufacturers, the answer lies in gaining deeper visibility into operations—cultivating operational intelligence that highlights optimization opportunities. One of the most effective tools in this transition is the digital twin. A digital twin is a virtual replica of a physical system, allowing manufacturers to simulate and analyze every aspect of their operation. By using industrial software, businesses can create a digital mirror of their entire manufacturing environment. This technology empowers them to monitor asset health, minimize maintenance costs, and optimize overall facility performance.
With near real-time digital simulations, manufacturers gain full visibility into their operations, enabling them to run critical tests and simulations before physical equipment is deployed. As digital twin technologies evolve, they provide manufacturers with new ways to model and analyze data more effectively, driving smarter decision-making. These innovations help companies accelerate timelines, improve product quality, and close the engineering feedback loop. Digital twins are helping businesses unlock hidden optimization opportunities, driving smarter, more efficient manufacturing operations.
Leading global companies, such as Phillips 66, are already using digital twin technology to enhance their operations. Phillips 66 utilized digital twin technology to create a unified simulation model, optimizing refining output and boosting situational awareness. By leveraging advanced industrial software, they integrated both physical and non-physical assets (like product streams and yields) into a single, centrally managed model. This dynamic approach led to improved operational transparency, optimized performance, and empowered employees with direct access to the models they need to make informed decisions. As manufacturing continues to get smarter, the benefits of integrating digital twin technology will only grow, driving innovation, increasing returns, and enhancing operational outcomes.
Manufacturing industries are facing a significant skills shortage as the workforce ages. With a growing number of workers over 60, and a lack of young, skilled talent entering the field, businesses are struggling to fill essential roles. In the U.S., millions of manufacturing jobs are expected to go unfilled in the next decade due to this skills gap. So, how can companies bridge this divide?
The answer lies in resilience. Effective knowledge transfer is crucial for business continuity, and digital technologies will play a pivotal role in capturing and sharing institutional knowledge. By organizing data flow and modeling business outcomes, companies can leverage the power of digital transformation to tackle the skills gap. Machine learning (ML) and advanced analytics can help streamline processes, allowing subject matter experts (SMEs) to focus on critical tasks, rather than getting bogged down with repetitive work. While these technologies aren't a complete substitute for human expertise, they significantly enhance efficiency, decision-making, and operational agility.
To thrive in this ever-changing landscape, manufacturers must optimize their workforce, processes, and technology to stay competitive. By combining human capital with digital tools, businesses can drive innovation and sustainability, ensuring they’re ready for the future of manufacturing.
The digital transformation journey in manufacturing presents both challenges and opportunities. By integrating smart technologies like digital twins, machine learning, and data modeling, manufacturers can improve operational efficiency, boost resilience, and drive greater agility. The future of manufacturing lies in the seamless combination of technology and human expertise—leading to more sustainable, innovative, and profitable business practices.
Are you prepared to elevate your manufacturing operations to the next level? With cutting-edge technologies like digital twins and AI, the possibilities are endless. Get in touch with ENI today to unlock the power of digital transformation and lead the way toward a more sustainable, efficient future.