When a Factory Digital Twin Earns Its Maintenance Cost

Give the model a job

A moving model of a factory can be impressive while leaving every production decision unchanged. Before commissioning a digital twin, finish a plain sentence: this model will help a named person decide a particular action using particular evidence. Perhaps an engineer must choose whether to inspect an unusual build, or a planner must compare two schedules. Those are different jobs and may require different models.

For this article, digital twin means a model maintained through an explicit connection to a physical process. That working definition is deliberately practical. It avoids arguing over whether a dashboard deserves the label. The first deliverable should be a description of the decision and the existing alternative, including a spreadsheet or an experienced operator's judgment. Without that baseline, a more elaborate display can be mistaken for an operational improvement.