Digital Twins: Unlocking Intelligent Edge IoT in Manufacturing – Part 2

In the first installment of this two‑part series, we introduced the digital twin concept and its role in visualizing manufacturing assets. In this second part, Sukamal Banerjee, Corporate Vice President – ERS Sales (Hi Tech & Comm) and Head of IoT WoRKS at HCL Technologies, examines the next major benefit: enhanced collaboration and the strategic questions that guide implementation.

Collaboration Is the Cornerstone

A digital twin’s true power lies in its ability to be shared in real time, regardless of geographic distance. By allowing multiple stakeholders to view, track, and benchmark machines on a global scale, it eliminates reporting delays, reduces single points of failure, and streamlines access to expert support.

With a digital twin, shop‑floor insights become available to product managers, designers, and data scientists. These teams can analyze productivity, redesign processes, and anticipate issues before they surface—saving time, cutting material waste, and exposing gaps between intended and actual performance. Root‑cause analysis becomes faster and more precise.

Unlike traditional 2D or 3D CAD drawings—which focus on static dimensional data for a single component—digital twins capture holistic, real‑time data on equipment interactions, environmental conditions, and system dynamics. They continuously ingest data such as spatial layouts, temperature, pressure, and vibration through a digital thread, keeping the virtual model in sync with the physical asset.

While CAD models primarily influence early design decisions, digital twins drive ongoing manufacturing and service operations, enabling continuous improvement.

Three Strategic Questions to Guide Your Digital Twin Journey

1. What critical operational insights will empower decision‑making? This determines the data sources and visualizations you need.
2. Which three to five business roles should the digital twin serve? Tailoring views to specific roles minimizes visual clutter and maximizes relevance.
3. What incremental roadmap will enrich the twin over time? Adding new data sets or expanding role access—much like Google Maps’ evolution—creates lasting value.

When executed thoughtfully, digital twins deliver a sustainable competitive edge: superior products, higher efficiency, and faster time‑to‑market. Start with small, focused pilots to demonstrate ROI, then scale to comprehensive systems that continuously reinforce success.

Author: Sukamal Banerjee, Corporate Vice President – ERS Sales (Hi Tech & Comm) and Head of IoT WoRKS, HCL Technologies.