The Benefits of Digital Twins for Predictive Maintenance in Manufacturing

May 12, 2023 | News

Manufacturing plants are complex systems that require predictive maintenance to reduce downtime and improve safety. The problem is that it can be difficult to know when and how to maintain equipment. This is where digital twins can help. Digital twins are a powerful tool for manufacturers looking to reduce costs, improve customer experience, and identify potential issues quickly.

What are Digital Twins?

Digital Twins are virtual replicas of physical assets, processes, or systems that use real-time data and analytics to simulate their behavior, performance, and interactions with the environment. They are essentially a digital representation of a physical object or system, created using a variety of technologies, including sensors, IoT devices, and machine learning algorithms. Digital Twins enable organizations to analyze and optimize physical assets and processes in a virtual environment before implementing them in the real world, providing valuable insights into performance, maintenance, and optimization opportunities.

Digital twins are already being used in a number of industries, including manufacturing, healthcare, construction and transportation and other industries where complex systems or processes need to be monitored and optimized for efficiency and productivity. The benefits of using digital twins for predictive maintenance are vast and include reduced downtime, improved safety, and increased efficiency.

What is Predictive Maintenance?

Preventive maintenance refers to a proactive approach to maintaining equipment or systems to prevent breakdowns or failures before they occur. It involves regularly scheduled inspections, testing, cleaning, and replacing parts to prevent potential issues and ensure that equipment or systems operate at peak performance. The goal of preventive maintenance is to increase the lifespan of equipment and avoid costly downtime or repairs.

Preventive maintenance can be time-based, where maintenance is scheduled at predetermined intervals, or condition-based, where maintenance is performed based on specific criteria, such as the number of hours of operation, usage levels, or other performance indicators.

Why Use Digital Twins for Predictive Maintenance?

Digital Twins can play a critical role in preventive maintenance by providing real-time data and insights into the condition and performance of equipment or systems. By creating a virtual replica of the physical asset or system, Digital Twins can monitor and analyze real-time data from sensors and other sources, such as temperature, pressure, and vibration levels. This allows for early detection of potential issues or anomalies that may lead to equipment failure or breakdown. With this information, maintenance teams can take proactive steps to address the issue before it becomes a major problem, reducing the likelihood of unplanned downtime or costly repairs.

Moreover, Digital Twins can also simulate potential scenarios or changes to the system, allowing maintenance teams to test different maintenance strategies and identify the most effective approach. They can help teams optimize maintenance schedules, predict future maintenance needs, and plan for the necessary resources and spare parts. Finally, digital twins make it easier to identify potential problems before they manifest. This gives manufacturers the ability to act upon any potential issues before they become costly.

By using Digital Twins for preventive maintenance, organizations can reduce the overall cost of maintenance, increase equipment uptime, and improve the lifespan of their assets.


Digital twins are increasingly being seen as a key asset for predictive maintenance in the manufacturing sector. They can help to reduce operational costs, ensure that products meet the highest standards of quality, improve asset performance, reduce the risks of downtime and help to ensure that the manufacturer remains competitive.

Digital twins for predictive maintenance can help manufacturers to identify potential issues early on, so that they can take corrective action before any major problems occur. As manufacturers become more comfortable with using digital twins, the technology will become an increasingly important part of their predictive maintenance plans. In the future, it is likely that digital twins will become an industry standard in the manufacturing sector.

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