Digital Twin - From Misbelieve to Achieve Practical Results!
Felipe Hoffmann, Automation Engineering and Digitization Manager , Grupo Boticário
Felipe Hoffmann, Automation Engineering and Digitization Manager , Grupo Boticário
We started our Digital Twin journey in 2021 after attending several industry 4.0 events and case studies. We did some benchmarking with companies from other sectors that were more advanced in the subject which was crucial to help us understand which issues we could solve with Digital Twin. In fact, we always look at technology as a means to solve our pain points or generate opportunities, but never as the end. Somehow, we had a lot of questions about how to generate value by using this technology. However, by joining case studies, as well as talking to advisors from trending companies, such as Gartner, which is our partner, we decided to create the Digital Twin Program, which had a cross functional team to explore the potential.
After that, we did some discussions around the term Digital Twin and what it means in our business and we move forward by dividing it into two pillars. The first relates to Assets Digitalization and the second to Process Simulations. Thereafter, we performed some ideation sessions with our multidisciplinary team to collect issues and business opportunities, divided into two pillars. We had a prioritization session where we decided to proceed with three initiatives. Firstly, factories digitalization by assets scanning process, generating point clouds, and finally 3D models. Over the process simulation pillar, we prioritize the bottleneck study and our real needs for investments in the Logistic area, due to our manufacturing capacity increase.
What did we do then? We developed the three prioritized initiatives, which resulted in our two factories being digitized with all assets in 3D models leveraging better organization and visibility of layout interferences that were previously unable to analyze. In addition, we’ve established governance around 3D models, in case of layout changes. Relates to the process simulation pillar, we achieved 98 percent of CAPEX investments assertiveness for Logistics. By using Digital Twin technology we managed to discover bottlenecks that would never be found otherwise. Finally, we carried out a simulation to set our gap to reach full capacity of the factory and we discovered that our maximum limit was just 25 per cent more, due to many restrictions, for instance logistic stocks. Afterwards, all CAPEX investments were set to increase just the target discovered. In summary, without simulation in this case, we could take wrong decisions where could affect the business strategy.
In Fact, We Always Look at Technology as a Means to Solve our Pain Points or Generate Opportunities, But Never as the End
Finally, we carried out a simulation to set our gap to reach full capacity of the factory and we discovered that our maximum limit was just 25 per cent more, due to many restrictions, for instance logistic stocks. Afterwards, all CAPEX investments were set to increase just the target discovered. In summary, without simulation in this case, we could take wrong decisions where could affect the business strategy.
Currently, we have advanced our maturity level by carrying out a new Assessment, which pointed to us that we are at an intermediate level because we are using the technology daily and it is a requirement to execute simulations before advancing in CAPEX investments. We got the lesson learned that there are no arguments against facts and figures. Then, we believe our Digital Twin is just at its beginning, however doubtlessly technology aggregates value. At last, this case has certified what we already believe, that technology is just a means to achieve our goals, and gave us a better sense of how important it is to run a pilot project! Run the pilot, measure the results, fail and pivot (if necessary), but get it done! It’s worth!
