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AIROI - Artificial Intelligence Return on Invest: The AI strategy for decision-makers and managers

26 May 2025

Industrial simulation twins (Glossary)

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The term "industrial simulation twins" is particularly at home in the fields of Industry and Factory 4.0, automation and artificial intelligence.

An industrial simulation twin is a digital image of a real machine, production plant or a complete factory process. With the help of modern software and data from sensors, a virtual model is created on the computer. This model "behaves" almost exactly like the real object and can be fed with current data in real time.

This means that companies can simulate processes without having to stop or rebuild the real system. They can see in advance what the effects of changes or errors would be. Here is an example: a car factory wants to introduce a new production line. Instead of converting machines and robots directly, everything is first tested virtually as a simulation twin. This allows engineers to detect potential problems at an early stage and optimise the system before it actually goes into operation.

Industrial simulation twins make it possible to save time, costs and resources - and help to make production safer and more efficient.

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