Improve business outcomes by pairing the virtual and physical in a Digital Twin

Background image: Digital Twin 2023 Kalypso

We help manufacturers deploy and maintain digital twins to model, monitor and optimize the operation of equipment, systems and processes.

The success of implementing new factory assets, systems and processes relies on accurate designs and on-time deployment. These designs are often built using assumptions, empirical calculation and historical experiences, which makes it difficult to account for variability.

Deployments are frequently delayed due to changes identified during commissioning on the shop floor. This dependence on trial-and-error to address unforeseen variability is inefficient, introduces project delays, increases risk and limits flexibility for future layout improvements.

Real Results

Digital twins deliver measurable business outcomes

  • Up to 15% OEE improvement
  • Up to 75% faster commissioning
  • Up to 40% reduction in reactive maintenance
  • Over 90% first-time operation success improvement

Unlock the Value of Digital Twins for Your Business

We help manufacturers rapidly deploy digital twins to optimize equipment design, shorten commissioning time, increase production throughput, improve training efficacy and reduce equipment maintenance cost. ​

Using virtual environments and AI new deployments can be efficiently evaluated and improved during the planning stages, before a single line is commissioned.

Icon Digital Twin Modeling


Understand how products and packaging interact with manufacturing equipment and gain insight into equipment location and user interfaces for operator ergonomics. Enable engineering to improve user experience and reduce training time by starting virtually before the physical system is built.

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Iteratively experiment and gain real-time feedback on design changes and system metrics.

Icon Digital Twin Emulation


Detect issues in equipment design, line layout and control system programming before equipment fabrication and physical testing.

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Integrate analytics systems with digital twins for real-time condition monitoring and analysis of asset performance against historical data. This enables manufacturers to predict failures and leverage designed maintenance routines to reduce downtime and upkeep costs.

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Immersive Experiences

Visualize the digital twin in a 4D environment where operators and other personnel can more effectively interact with the model, improving the applicability and value of the digital twin.

How We Help Companies Deploy Digital Twins

We build digital twins of varying complexity to meet the requirements of industrial and material handling organizations.

Object Twin

A digital representation of a basic part or component within a system that is used to model the lifecycle of a single part or product.

System Twin

A digital aggregation of multiple object twins, that is used to model the interaction between components/parts over the system’s lifecycle.

Process Twin

A digital representation of the sequence of process steps that models the interaction of ingredients and/or components that combine to create an output product.

Multi-System Twins

A representation of multiple system/process twins operating in a business-defined environment, modeling the highest order of systems to provide a macro-view of the environment.

Our methodology focuses on delivering immediate value, while enabling companies to scale and sustain the capabilities across the organization.

To prove the business value, we apply a minimum viable product (MVP) approach to digital twin projects, addressing the highest-impact use cases first, before scaling the solution to additional opportunities.


  • Assess the organization’s readiness
  • Define clear strategy
  • Identify high-impact use cases
  • Gather modeling assets


  • Build digital twin model with existing CAD
  • Replicate real-world movements with control logic
  • Analyze and optimize control logic via simulation/emulation
  • Measure the results and make refinements


  • Expand digital twin capability to more assets, systems and sites
  • Transfer knowledge to resources that will own, operate and maintain models
  • Increase adoption across all functions
  • Measure and realize enterprise-wide value

Use Cases

Digital twins pair the virtual and physical worlds enabling informed decision-making through historical data analysis, real-time system monitoring, simulations and emulations.

Design Prototyping: Rapidly prototype engineering changes and validate with physically accurate simulation to identify and anticipate opportunities for design improvements.

Virtual Commissioning: Accelerate commissioning by developing and testing PLC code virtually.

Operations Research: Improve operations by optimizing scheduling, material routing, resource allocation and more via simulated optimization testing.

Production Execution/Optimization: Supervise and improve operations with remote monitoring, management, maintenance and assistance capabilities.

Immersive Experiences: Create compelling 3D experiences for operator training or sales to improve end-user product/system interaction.

Intelligent Model Training: Accelerate the training and deployment of AI into production systems with robust and physically accurate simulation.

Primary Digital Twin Technologies

Thought Leaders