Why Digitalization and Sustainability Go Hand in Hand?
Imagine a production facility where machines, equipment, and systems not only work together perfectly, but also conserve energy and resources at the same time. In this Smart Factory, data is recorded, analyzed, and used in real time to make processes more efficient and even more sustainable. What may sound like a distant dream at first sight is in fact reality today and we owe this to the so-called “Twin transformation.”
Twin Transformation combines two key objectives that are decisive for the success of any manufacturing company today: consistent digitalization and the sustainable design of all processes. However, these are by no means two separate developments. It is rather a case of twins that strengthen and drive each other forward. Just like two cogwheels that mesh perfectly and together provide the drive for sustainable manufacturing. The “twins” offer manufacturing companies brand new opportunities to increase their efficiency, save resources, and meet environmental protection requirements simultaneously.
What is the story behind this?
Digitalization means intelligently networking processes, machines, and data streams to increase transparency, flexibility, and efficiency throughout shop floor management. Innovative manufacturing IT records and analyzes data from production in real time. Companies can, for example, precisely monitor the energy consumption of individual machines or control material flows in the best possible way.
Sustainability is not only a buzzword in our days. The key is to conserve resources, reduce emissions, and close cycles at all levels of the value chain. In today’s increasingly complex manufacturing world, this would be virtually impossible without digital support. Only those who know their processes inside out and can control them are able to identify opportunities for optimization and implement sustainable improvements.
Digitalization is not an end in itself – it rather unfolds its full potential when it makes a systematic contribution to achieving sustainable goals. In turn, sustainable action also becomes more efficient and effective when it is based on a solid digital foundation. The Twin Transformation unites these two forces and paves the way for a Smart Factory that combines economic success with ecological responsibility.
Use cases from the Smart Factory: Where does digitalization meet sustainability?
The Twin Transformation is particularly impressive in specific applications in the Smart Factory. Here, digital technologies and sustainable goals merge to ensure overall progress. In the following, we present typical use cases where digitalization and sustainability go hand in hand:
- Energy and resource monitoring
Digital sensors and manufacturing IT systems such as a Manufacturing Execution System (MES) record energy and resource consumption in real time. Companies can thus identify potential savings and take targeted measures to reduce their consumption of energy, water, or materials. - Predictive maintenance
Data-driven maintenance makes it possible to service machines when necessary. This extends the service life of equipment, reduces the need for spare parts, and minimizes downtime, thereby saving resources and costs. - Optimized production planning with APS
An Advanced Planning and Scheduling System (APS) plans orders in such a way that machines are running more efficiently, and changeovers are minimized. Planning with an APS reduces energy consumption and provides for a more economic use of all resources. - Digital traceability for circular economy
Seamless data recording permits the tracking of material usage from raw materials to the final product, which facilitates recycling processes and supports sustainable circular economy strategies. - System integration with platform architecture
An integration platform connects different IT systems and creates a continuous data flow. Only then can sustainability goals be managed in their entirety and new, innovative use cases be implemented.
Twin Transformation at work
For example, a medium-sized manufacturing company is using MES HYDRA X to record machine data. They use APS FEDRA for resource-efficient planning. The company uses the Manufacturing Integration Platform (MIP) to integrate the different IT systems into a complete solution. The result: lower energy consumption, less waste, greater transparency, and a significant step toward a sustainable Smart Factory.
These use cases impressively demonstrate how closely digitalization and sustainability are now interlinked. Companies that exploit the potential of twin transformation in their own production processes are positioning themselves perfectly for the challenges of the future while also making a contribution to protect the climate.
Twin Transformation as a success factor for the Smart Factory
Twin Transformation is much more than a short-lived trend: it is the key enabler for sustainable manufacturing. Those who systematically combine digitalization and sustainability not only build efficiency advantages within their own companies, but also meet the increasing demands of the market and legislators. The combination of both approaches makes companies more resilient, innovative, and economically successful and reducing their carbon footprint at the same time.
With the right manufacturing IT, transparency, controllability, and sustainability in the shop floor can be elevated to a new level. As a result, resources can be used optimally, emissions reduced, and competitiveness increased at the same time.
Why act?
Now is the right time to take a step toward Twin Transformation and align your own manufacturing processes with the requirements of the future. Take advantage of the opportunities offered by digitalization to create sustainable value – for your company, your customers, and the environment.
We, the experts at MPDV, are happy to support you with our expertise on your way to the Smart Factory! Do you have any questions or want to know more? Contact us or share your experiences with us – we are looking forward to a lively exchange!
The author was assisted by artificial intelligence in creating the text. Relevant text passages were carefully checked and manually revised where necessary.