Power2 - Digital twin as an essential component of intelligent networking

Have you ever heard about Doubleganger?

This English-German term was initially used by Dr. Michael Grieves, who introduced the concept of Digital Twin (or less familiar: Product Lifecycle Management) to the world at the beginning of this century.

In his concept paper (PDF) Dr. Grieves wrote:

This digital information would be a “twin” of the information that was embedded within the physical system itself and be linked with that physical system through the entire lifecycle of the system.

The idea of connecting different processes and exchanging data between physical systems and their digital representations was already here in the 1990ies. Still, only new technology enables us to implement Digital Twin. Even more,

“Digital Twin” is a cornerstone for the 4th Industrial Revolution.

Deloitte Insights came to this bold conclusion some years ago, and I highly recommend you this research. It focusses on digital manufacturing, but the concept – and implementation of Digital Twin has a universal approach. In Deloitte’s actual Whitepaper “Grenzenlos vernetzt” (in German), they state that “Digital Twin makes IoT smarter”.

Regarding Logistics, they represent an interesting thesis:

Digital twins simulate, visualize, and optimize the flow of materials; real-time monitoring of the utilization of logistical processes and fully networked fleet management becomes possible.

Personally, this makes me delighted: I think there has never been a more exciting time for industries and logisticians to work together to leverage the full potential of the digital twin. I want to share some of my thoughts on this.

Digital Twin in Logistics

Digital simulation models, digital twin, already exist for different products and processes.

And what about Supply Chain, any ideas?

I’m sure: as the logistics sector deals with complex and global operations, it is a long-term project to build a virtual and comprehensive copy of E2E supply chain networks. I want to discuss three examples of digital twin influence on the supply chain with you.

If you think of digital twin as digital or 3D versions of machines, cities, devices, and products, you are right and wrong. CAD (computer-aided design) software has been helping to describe a physical state digitally since the 1960s. However, a digital twin goes further. It is a virtual model equipped with sensor technology and gives data insights also about external circumstances or devices it is related to.

We are living in exceptional times: Learnings from the past and proactive approaches become possible through these dynamic virtual models that, by the way, do not have to be identical copies. The focus is on relevant parameters that can be measured, manipulated, and compared.

Please keep in mind: Digital Twin shouldn’t be equated with its physical origin. It’s rather a simulation, which assists and helps us to collect available data about the situation. We should consider the data, but also be cautious about reality.

I see three ways how parts of the logistics supply chain are positively influenced by digital twin already: Digital Twin provides you with essential knowledge:

1. To know where the freight is (according to the available data)
2. To know how the conditions of the freight are
3. To know who your stakeholders within the data flow are

1. WHERE: To know the current location of the Freight

You will surely agree with me on this: one of the most crucial topics for logistics enterprises is the knowledge about the asset that transports the goods and the freight itself - be it on trucks, train wagons, ships, planes, or in a warehouse. This is where digital twin comes into play. If all the assets and cargo are equipped with communicating sensors, a valuable source of real-time tracking data is created. It helps to keep an overview of the position. I believe it will underline the trustworthiness and reliability of the logistics company if we have these insights and deliver them to clients.

Even more: It is of great advantage to know how cargo can be transported in the fastest way. Through the connection to GIS (Global Information Systems) - i.e. data about weather, roads, and traffic - logistic carriers are enabled to operate based on real-time or historical data and calculate predictive patterns. Thereby digital twin determines the choice of transport routes intelligently.

I am sure that detailed information about the exact dimensions and every angle of the shipping vehicle delivers digital value. Capacity planning and loading are facilitated by data paired with software that tells the carrier how much space can be used, and which dimensions the cargo needs to have. It can, as a long-term effect, even result in different and realigned loading strategies. Without sensors and the data available, these carriers would remain blind spots – a potential cause for carriers not running at full capacity and empty miles. In the bigger picture, it would mean an increased carbon dioxide footprint.

2. HOW: To know the conditions of the Freight

That’s the fact: the shipping in the B2B world is multifaceted - from customer-specific smaller charges till larger quantities in huge, at best reusable containers. Understanding how long containers should be used and when they are ready for maintenance is inevitable for a sustainable business. With the help of assistance systems using real-time 3D sensors, the digital twin is created. They help operators detect where potential flaws are. I suppose this kind of software can also be used to analyze past data and activities of this container. Thereby it illuminates under what condition (shocks and location of occurrence, extreme temperatures, and humidity) the container breaks faster, or might develop a higher frequency of maintenance. At best, the collected data can be paired with the position data, so the place of occurrence is also captured. Innovative packaging material can also be equipped with sensors and connected to software – thereby, cargo is continuously monitored, and product requirements are met uncompromisingly.

3. WHO: to know your stakeholders within the data flow

I am sure: there are already significant improvements through digital twins in different parts of a supply chain. However, it is the main goal to connect different processes and enable them to exchange data dynamically. As there is more data needed for network-orientated digital twin – there will be several stakeholders involved. Besides logistics carriers, it could potentially involve governments, relevant authorities, airports and aviation companies, ports, operators of railways and roads and manufacturers, navigation software firms. A mutual interest group would need to push frictionless and seamless on-site and satellite data collection along digital roads, moving devices and goods, trackable vehicles (be it trains, cars, or trucks), and the corresponding environment.

You see now: Given the immense cost and maintenance, an open API strategy defines the dimension of success. As my article shows – digital twin is highly relevant along the whole supply chain. The key to developing digital twins will be the interconnection of them. To create vivid, predictive digital models instead of static ones, future and past data should be available and integrated. Given these goals and the strong potential of impact, it is inevitable to create open-source models and platforms so that stakeholders can access data and add new data - bit by bit.

Last but not least, figures speak for the relevance of technologies best. So, let me close this article by sharing with you that 

"Four out of ten companies plan to create and use digital twins within the next five years."

That’s the proof that the digital world is moving, but slowly. If your company has pushed forward IoT topics and a digital twin; it might take several years and business partners more to harvest the fruits of data and its infrastructure.

What do you think: Is it ever possible for the scattered logistics business to create digital twin with impact? What would have to change? How long would it take? And: do you already implement the Digital Twin concept in your industry?