Digital Twin Technology for Small and Medium-Sized Enterprises in Industrialised Automation
- DelaControl
- 4 days ago
- 2 min read
Digital twin technology is now within reach for small and medium-sized enterprises (SMEs), not just large corporations. By creating virtual representations of physical assets, processes, or systems, digital twins help SMEs boost efficiency, reduce downtime, and enhance competitiveness in a digital world.
What Is a Digital Twin?
A digital twin is a virtual model mirroring a machine, process, or system, updated with real-time data from sensors and control systems. For SMEs, a digital twin of a pharmaceutical packaging machine can predict motor wear, cutting maintenance costs by 10–20% (per McKinsey). This allows managers to test scenarios and plan improvements without disrupting production.
Why Digital Twins Matter for SMEs
Digital twins deliver key benefits for SMEs:
Reduce downtime by 20% through predictive maintenance, avoiding costly stoppages (per Rockwell Automation).
Enable rapid testing of recipe changes or machine set-ups, saving 20–30% on prototyping costs.
Optimise capital investments by modelling new equipment performance before purchase.
Support workforce training in safe, simulated environments, minimising errors on complex machinery.
These features, aligned with standards like ISO 55001, enhance efficiency and decision-making for SMEs.
Practical Routes to Adoption
SMEs can adopt digital twins without a full smart factory overhaul:
Start with critical assets, such as bottleneck machines, to address high-impact downtime.
Use existing tools, like Siemens TIA Portal with SIMIT, costing £5,000–£10,000, to build digital twins.
Leverage cloud platforms, such as Microsoft Azure at £1,000/month, for affordable data processing.
Partner with integrators to ensure secure, scalable projects, integrating with legacy systems.
These steps make digital twins cost-effective for SMEs.
Benefits for UK Manufacturing SMEs
UK SMEs face high energy costs (£0.20/kWh in 2024), skills shortages, and global competition. Digital twins address these:
Cut energy use by 8% through real-time optimisation (per ABB).
Ensure compliance in sectors like food manufacturing, supporting ISO 22000 traceability.
Speed innovation by testing product designs virtually, avoiding production risks.
For example, a food SME uses digital twins to optimize batch processes, meeting regulatory demands.
Overcoming Challenges
Cost, expertise, and legacy system integration are barriers, but sensors costing £50–£200 (down 30% since 2020) and cloud solutions ease adoption. Upskilling via programmes like Made Smarter or partnering with technology providers helps SMEs integrate digital twins with older PLCs.
The Future for SMEs
As Industry 4.0 advances, AI will make digital twins 90% accurate in predicting failures, and standardised platforms will lower costs. AR-integrated digital twins will enhance operator training. SMEs adopting digital twins early will gain efficiency and resilience. UK SMEs should pilot digital twins now to stay competitive.
Conclusion
Digital twin technology is transforming industrial automation, empowering UK SMEs to compete with larger players. By targeting critical assets, using tools like Siemens TIA Portal, and focusing on outcomes like 8% energy savings, SMEs can reduce downtime and optimise processes. As AI and AR enhance digital twins, UK SMEs must adopt this technology to thrive in a fast-moving manufacturing sector.
