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Digital twin in manufacturing
A model of your process, synchronised with production in real time.
What is a digital twin?
A digital twin doesn't just show what is happening, it calculates what should be happening — and sends the decision back to production. It is the technology every Dween solution is built on.
A digital twin is a digital counterpart of a real process or piece of equipment that continuously receives data from production and updates itself from it. It “knows” what the equipment can do, the technological constraints and the logic of the process, so it can calculate what will happen if you change something, and which decision is the best one right now.
In industry, digital twins are used where there are too many decisions for a person to weigh up in time: where the process keeps changing, there are many variables and mistakes are costly.
How is a digital twin different from SCADA and ERP?
| System | What it does | What it doesn't do |
|---|---|---|
| SCADA / PLC | Shows and controls the current state of equipment according to set values | Doesn't calculate which values would be best |
| ERP | Stores orders, deadlines, stock and finances | Doesn't know the real state of equipment and doesn't calculate the best plan in real time |
| Digital twin | Continuously synchronised with production, calculates the best decision and sends it back | — |
Dween doesn't replace your SCADA, PLC or ERP. It works on top of them: it reads their data and returns decisions to the same systems.
Which technologies are used?
Digital twin
A model of your process, synchronised with production in real time.
Machine learning
Plan-versus-actual comparison, root-cause analysis and insights. The model learns from your production history.
Optimisation
The CP-SAT constraint programming method (Google OR-Tools) finds the best solution when there are many interdependent constraints.
Automation
Tasks are passed to production automatically.
What data is needed?
No new equipment. Dween uses the data already in your systems.
What we need from you: a virtual machine with internet access, a VPN, and the OPC or PLC tag addresses.
- ERP
- Orders, deadlines, stock, recipes
- SCADA / PLC
- Equipment status, temperatures, pressures, energy consumption
- Production logs and Excel
- If some information isn't digital yet, we digitise it during the rollout
How does the rollout work?
The whole rollout takes up to 6 months from signing the contract, without disrupting production.
Data collection
Dween DataHub is installed and the data sources are connected.
up to 1–2 monthsVisualisation and preparation
The data is visible in the Dween environment in real time, and the quality of historical data is checked.
up to 1–2 monthsDigital model and automatic control
The model is calibrated to real production conditions and integrated with your systems.
up to 2–3 monthsResults
Actual payback: 2–7 months, against a promised 12 months.
All success stories →
Security
ISO 27001 certified information security, compliant with NIS2, the Data Act and the AI Act. Data is transferred over a VPN, and decisions are returned only to the systems you specify.
FAQ
What is a digital twin?
A model of a real process or piece of equipment, continuously synchronised with production data. It calculates which decision is best right now and sends it back to production.
Do we need to replace our ERP or SCADA?
No. Dween works on top of your existing systems, reads their data and returns decisions to them.
Do we need extra sensors?
Usually not — the SCADA, PLC and ERP data you already have is used.
How long does the rollout take?
Usually up to 6 months from signing the contract to a working digital twin.
Is a digital twin considered artificial intelligence?
Yes. Lithuania's EU-funded call “Deployment of artificial intelligence solutions” lists digital twins as one of the supported AI areas.
Is your production using its full potential?
Get in touch — we'll assess what a digital twin could do for your process.