Digital Twin Platform for Smart Factory
A factory operator needed to simulate production line changes before physical implementation to reduce costly trial-and-error downtime.
Team
8 engineers + 2 simulation specialists
Timeline
22 weeks end-to-end
Client
Smart Factory Operator
Outcomes Delivered
78%
Simulation-to-Reality Accuracy
60%
Change Implementation Cost Reduction
3 weeks → 2 days
Production Line Reconfiguration Time
How we delivered it
Instrumented the production floor with 350 sensors covering machine state, throughput, energy consumption, and material flow.
Built a 3D digital twin model using Three.js with real-time sensor data overlay, enabling operators to visualise the factory state remotely.
Developed a discrete event simulation engine (C++) that models production line behaviour, enabling what-if scenario testing without physical disruption.
Integrated the simulation engine with the ERP system so production planners can test schedule changes before committing to the shop floor.
Delivered a change impact assessment tool that quantifies the cost, time, and risk of any proposed production line modification before implementation.
What we built
Built a real-time digital twin of the production floor using IoT sensor data, 3D modelling, and a simulation engine for what-if scenario testing.
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