TL;DR: Digital twins, virtual replicas of physical operations, help manufacturers make faster, smarter decisions by providing real-time production insights. For Virginia’s manufacturers, they optimize processes, boost capacity, lower costs, and enhance competitiveness.
The manufacturing world is under pressure—tight margins, labor shortages, and supply chain disruptions are forcing companies to find smarter ways to work. One of the most powerful tools leading digital manufacturing? Digital twins.
These virtual replicas of physical operations give manufacturers real-time insight into production, enabling faster, smarter decisions. For Virginia’s manufacturers, digital twins are becoming a key tool for manufacturing process optimization—boosting capacity, lowering costs, and staying competitive.
Let’s break down what they are, how they work, and how partners like GENEDGE help make them work for you.
Table of Contents
- What Is a Digital Twin?
- Why Digital Twins Matter Right Now
- How Digital Twins Work in the Factory
- What You Need To Get Started
- How GENEDGE Supports Your Digital Twin Strategy
What Is a Digital Twin?
A digital twin is a real-time, virtual model of a factory, process, or system. It reflects live conditions on the shop floor and allows manufacturers to simulate scenarios, test ideas, and optimize performance—without interrupting operations.
Think of it as a digital sandbox. Instead of relying on spreadsheets or gut instinct, you can model outcomes of changes like adjusting batch sizes, reworking layouts, or launching new product mixes.
Why Digital Twins Matter Right Now
According to a 2024 McKinsey survey, 86% of manufacturers say digital twins are relevant to their operations—and for good reason. They’re helping solve some of today’s biggest challenges:
- Limited production visibility
- Labor and material shortages
- Fluctuating demand and delayed deliveries
- Energy simulation
Digital twins are delivering real-world results, including:
- 4–7% monthly cost reductions through smarter scheduling
- Uncovering hidden bottlenecks
- Reducing machine downtime through better sequencing
- Improving warehouse layout and inventory management
How Digital Twins Work in the Factory
Digital twins connect data from machines, inventory systems, and ERP platforms into one model of your shop floor. With that model, manufacturers can:
- Simulate different production sequences
- Predict how layout changes will impact efficiency
- Identify where the equipment is starved or blocked
- Spot opportunities to reduce downtime and waste
With AI and machine learning, some digital twins take it further—automating simulations and adapting to real-time changes for continuous optimization.
What You Need to Get Started
Getting started with a digital twin takes more than just software. You’ll need:
- Clean, connected data from machines and systems
- A scalable tech stack that can grow with your operations
- Simulation and optimization tools
- A clear implementation and training plan
GENEDGE supports Virginia manufacturers with resources and tools for small manufacturers and larger firms alike to help take those first steps. We also fill technical gaps with:
- Data integration and modeling
- AI-powered optimization
- Cybersecurity
- ISO 14001/50001 implementation
How GENEDGE Supports Your Digital Twin Strategy
Whether you’re just exploring or ready to roll out a digital twin, GENEDGE is here to help every step of the way.
We offer:
- Online training/manufacturing programs to build in-house skills
- Access to simulation and digital twin technologies
- Guidance on integrating digital twins with lean and smart manufacturing practices
- Expert consulting in plant layout, energy management, and more
We’re also deeply connected to Virginia’s smart manufacturing ecosystem—partnering with leaders like Link Lab and Siemens to keep manufacturers on the cutting edge of IoT, AI, and automation.
Get Started with GENEDGE
The first step in growth strategies for manufacturing companies is understanding where you stand—and where you can go with the right technology. GENEDGE helps small and mid-sized manufacturers across Virginia turn advanced ideas into real-world improvements.
Not sure where to start? We offer resources and tools for small manufacturers that lay the foundation. From data to training, we’ll help you build a system that works.
Request a No-Cost Assessment and see how GENEDGE can help bring the power of digital twins to your operations.
