Digital twins (DTs) are becoming an integral part of modern industry, helping enterprises optimize production, improve product quality, and reduce costs. However, successful implementation is impossible without well-defined standards that ensure compatibility, reliability, and data security. This article explores why standards are essential for manufacturing digital twins, what problems they solve, and what challenges companies face during implementation.
What Is a Manufacturing Digital Twin and Why Is It Needed?
A manufacturing digital twin is a virtual representation of a physical object or process that collects, analyzes, and simulates data in real time. It typically consists of the following components:
- Data — information collected from sensors and production systems
- Models and algorithms — mathematical and analytical tools that predict system behavior
- Integration interfaces — mechanisms that connect the physical asset with enterprise IT infrastructure and analytics systems
Core Functions of a Manufacturing Digital Twin:
- Real-time monitoring and diagnostics of equipment
- Predictive maintenance and failure forecasting
- Optimization of technological processes
- Personnel training and simulation of various production scenarios
- Support for decision-making in production management
- Demand forecasting, logistics optimization, and delivery precision
Why do digital twins need standards?
Without well-established standards, digital twins risk becoming disjointed and ineffective, unable to integrate with other production systems. Key reasons why standardization is critical:
- Compatibility. Production environments involve many software platforms and automation systems. Shared standards allow seamless integration with existing ERP, SCADA, and MES systems.
- Data Reliability and Accuracy. Without standardization, there is a high risk of working with fragmented data, leading to inaccurate predictions and poor decision-making.
- Security and Information Protection. Digital twins store sensitive production data. Cybersecurity standards help protect that data from leaks and cyberattacks.
- Simplified Implementation. Unified requirements reduce the complexity of integrating new solutions, ensuring faster adoption across the enterprise.
- Cost Optimization. Standardized systems minimize expenses related to adapting proprietary technologies.
Which standards are being developed?
At the international level, several key standards are under development to create a unified framework for digital twins:
- ISO 23247 – defines architecture and principles for digital twins in manufacturing
- ISO/IEC 30182 – provides a data framework for cyber-physical systems, including DTs
- IEC 62264 (ISA-95) – enables IT/OT integration and ensures DT compatibility with industrial systems
- NIST Cybersecurity Framework – outlines data protection and cybersecurity guidelines for DTs
In Russia, work is also underway to develop a regulatory framework for digital twin implementation. National digitalization programs aim to adapt international standards and develop domestic specifications.
Challenges of implementing standards
Despite their advantages, standardization brings several challenges:
- High Modernization Costs. Upgrading IT infrastructure to meet standards can be expensive.
- Lack of Unified Terminology and Approaches. Many standards are not yet tailored to specific industry needs, complicating their application.
- Resistance to Change. Standard implementation requires employee training and workflow restructuring, which may face internal resistance.
- Cybersecurity Management. The more data exchanged between systems, the higher the risk of breaches. Maintaining up-to-date security measures is essential.
- Need for Testing and Pilot Projects. Before scaling up, companies must validate standards through controlled pilots.
SalesSolution addresses these challenges by developing its own digitalization strategies. For instance, the company tests solutions on small production sites before scaling them, helping reduce risk and improve the effectiveness of digital twin deployment.
Conclusion
Manufacturing digital twins are a powerful tool for increasing enterprise efficiency, but they require clear standards to succeed. Standardization ensures interoperability, data accuracy, security, and cost-effective integration of new technologies.
At the same time, companies must overcome hurdles such as infrastructure upgrades, cybersecurity demands, and process adaptation. Firms like SalesSolution are already implementing effective strategies to minimize risks and fully leverage the benefits of digital transformation.
The future of industry lies in digital twins — and their success depends on smart standardization and thoughtful implementation.
