Building Resilience Step by Step: Practical Adoption of Digital Twins
For many industrial and energy companies, the idea of deploying a full-scale digital twin across every asset can feel overwhelming. The reality, as highlighted during IIoT World Energy Day 2024, is that successful adoption doesn’t happen all at once—it happens incrementally.
Start Small, Scale with Success
A common message from industry leaders is: don’t try to do everything at once. The most effective digital twin projects begin by addressing a single pain point—whether that’s monitoring pipeline efficiency, improving Overall Equipment Effectiveness (OEE) on a production line, or simulating water treatment performance.
Once this first use case demonstrates value, companies are better positioned to expand. Each step builds confidence, establishes standards, and proves ROI, making it easier to scale digital twins across facilities and processes.
Simulation as a Low-Risk Entry Point
One of the most accessible starting points is using digital twins for simulation. Running “what-if” scenarios—such as adjusting flow rates, changing energy usage parameters, or reconfiguring a production line—allows companies to test decisions in a safe, virtual environment before making costly physical changes.
This not only reduces risk but also shows tangible value quickly, creating momentum for broader adoption.
Resilience Through Modular Growth
Panelists emphasized the importance of a “Lego-like” approach—building digital twin capabilities piece by piece. Instead of a massive, one-time deployment, organizations can add new layers over time:
- Monitoring and visualization as the foundation.
- Simulation for optimization as a next step.
- Integration with enterprise systems for decision-making at scale.
- AI and natural language tools to make insights more accessible.
This modular growth ensures that digital twins evolve alongside the organization’s needs and budget, while continuously enhancing resilience.
People as the Constant in the Journey
Even with incremental adoption, people remain central. Operators, engineers, and IT teams all play roles in shaping each stage of deployment. Training, collaboration, and change management ensure that every new layer of digital twin capability is not just installed but embedded into workflows.
Key Takeaway
Digital twins don’t have to be daunting. By starting small, focusing on real problems, and scaling step by step, manufacturers and energy companies can unlock business resilience without the risks of a “big bang” deployment. The path forward is not about doing everything at once—it’s about building resilience one success at a time.
Source: Mirroring Success: Digital Twins and Their Strategic Role in Business Resilience session at IIoT World Energy Day 2024
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