THE factory of the future will be a building stuffed full of robots making robots. A factory in Amberg, a small town in Bavaria, is not quite that, but it gets close. The plant is run by Siemens, a German engineering giant, and it makes industrial computer-control systems, which are essential bits of kit used in a variety of automated systems, including the factory’s own production lines.
The Amberg plant is bright, airy and squeaky clean. It produces 15m units a year—a tenfold increase since opening in 1989, and without the building being expanded or any great increase in the 1,200 workers employed in three shifts. (Production is about 75% automated, as Siemens reckons some tasks are still best done by humans.) The defect rate is close to zero, as 99.9988% of units require no adjustment, a remarkable feat considering they come in more than 1,000 different varieties.
Such achievements are largely down to the factory’s “digital twin”. For there is another factory, a virtual version of the physical facility that resides within a computer system. This digital twin is identical in every respect and is used to design the control units, test them, simulate how to make them and program production machines. Once everything is humming along nicely, the digital twin hands over to the physical factory to begin making things for real.
The digital twin is not a new invention. The concept of pairing traces its roots to the early days of space travel, when NASA built models to help monitor and modify spacecraft that, once launched, were beyond their physical reach. As computer power increased, these analogue models turned into digital ones.
The powerful systems that have since emerged bring together several elements—software services in computer-aided design and engineering; simulation; process control; and product life cycle management. Some digital twins are gaining artificial intelligence and virtual-reality capabilities, too. They can also help to monitor remotely and provide after-service for products that have been sold. “It is a digital twin of the entire value chain,” says Jan Mrosik, the chief executive of Siemens’s Digital Factory Division.
Siemens is not alone in equipping its factories with digital twins. Its American rival, GE, is doing the same. Both companies also sell their digital-twin software, along with firms such as Dassault Systèmes, a French specialist in the area.
