The CEIT Digital Twin Platform

The CEIT Digital Twin Platform is a unique, comprehensive software tool for designing, monitoring, planning, managing and optimising production and logistics systems. This tool creates the holistic ecosystem of a digital twin and leads to an Industry 4.0 digital transformation with the desired effect of optimising resources, increasing quality, reducing costs, detecting anomalies and making processes more effective.

The CEIT Digital Twin Platform is made up of three worlds dividing it into layers. The first consists of physical elements (machines, material, logistics technology etc.). The second consists of their digital equivalents: so-called digital twins. The third world is the level of data analysis, which processes informative data used for decision-making, setting out rules and adjusting the system.

The extent of the applicable analyses begins with the diagnostics needed for reactive decision-making, such as descriptive analysis (description and warning), diagnostic analysis (identifying causes), continuing through movement statistics (tracing – spaghetti diagram, intensity – heat maps) all the way to prediction (predictive analysis), pro-active decision-making and optimisation (prescriptive analysis). The data makes it possible to identify narrow places, eliminate unreliable technology or the human factor, analyse breakdowns, search for the causes of problems and thus optimise production and logistics processes in industrial companies. The management of the data flow is adapted to meet the requirements of interoperability between each element in the system. In order for the data to be closer to the places where decisions are being taken, it uses the decentralised architecture of a production and logistics system.

The virtualisation of data thus gives them a new added value, since it enables the intelligent and agile management of production and logistics systems and process in real time. The data does not only interpret information on the condition of elements in the production and logistics system, but also on process conditions. This thus makes the CEIT Digital Twin Platform a source of information for planning and decision-making across all departments such as production planning, logistics, industry engineering, health and safety, ergonomics, maintenance and human resources.

CEIT Digital Twin Platform_scheme_en

Advantages of implementation:

  • Comprehensive
  • Interoperability
  • Decentralisation
  • Virtualisation
  • Dynamic simulation
  • Virtual training
  • Artificial intelligence
  • Data analysis

Technologies used:

  • Communication with AGV systems is ensured using industrial standards
  • Communication with manually-controlled handling elements is ensured using UWB RTLS technology which enables an indoor localisation precision of 0.5 m

The system consists of a communications interface and four basic modules:

Modul projektovania procesov a kapacitného plánovania výroby

Process design and production capacity planning module

Modul monitorovania

Monitoring module

Modul riadenie a navigácie

Management and navigation module

Modul virtuálnych tréningov

Virtual training module

Communications interface

The integration module consists of a set of connectors which connect the layers of physical elements with layers of virtual reality. The layer of physical elements consists of production machines and equipment, logistics means, MRP/ERP system (production documentation, production plans etc.) as well as operators with their skills and experience. It provides information on the physical layer in order to enable computer processing, either active or passive.

Process design and production capacity planning module

The module is composed of a parametric model, which is a digital copy of the given system. It is divided into several hierarchical levels, with each level containing images of physical and non-physical objects, elements such as production machines and equipment, logistics means, operators and above all processes and their data. The virtual process connections (technological procedures, logistics processes, logistics operations, material flows) are on a separate level. This model allows the user to plan and organise the capacity of individual processes in the production and logistics chain. The digital copy’s task in this product is to set optimal processes using a set of visualisation, simulation and prediction tools.

The dynamic simulation can check different actions and solutions such as the production plan if certain data is modified or entered before their implementation. It can identify potential sources of problems and narrow places, thus enabled more effective decisions to be taken, which will meet the client’s demands on a daily basis.

Process design and production capacity planning module
Monitoring module

Monitoring module

Using the software modules in AGV technology and the smart sensor network based on UWB technology, it monitors all the production and logistics technology elements. The object of the monitoring is the collection of real-time data to inform about current operations in the production process and to record them as “digital shadows” in the database for further analysis, evaluation, prediction and above all operational management.

It monitors positions in time, the occupation rate of the technology, the need for a number of operators in a given work station, the level of skills, conflicts, down time, maintenance, collision situations as well as material handling.

Management and navigation module

Based on the information collected from each equipment, and on the requirements from the production and logistics processes, the system ensures decision-making and the subsequent management of each part of the production and logistics process. It manages the movement of each AGV, for example across crossroads, traffic lights, operation points, chargers etc., automatically and without the need for human intervention. Since the system communicates with the production plan, the free capacity of the production staff and handling equipment can be used efficiently by dividing up automatically the relevant operators in the right number, with the right work competencies for the work stations in the case of production staff, as well as sending maintenance staff to service interventions (TPM).

Management and navigation module:
Virtual training module

Virtual training module

Module of a virtual world, which is a 3D copy of the real world in real time with real process data. The training runs in the POV (Point of View) camera regime, where the system takes the trainee through the tasks in a virtual copy of the given world, and where they can try out each step without causing damage or losses to the company.

CEIT Digital Twin Platform gives the client the following:

  • A new agile production system able to react effectively to the required production volume while saving costs and production capacities
  • Collected and evaluated data, used to calculate KPI in real time and displayed on control panels and in reports
  • Thinking transformed from reactive to proactive
  • Development of team members and of the whole organisation by learning new skills and transforming work actions
  • A knowledge database for further development, as a key element for maintaining a high standardisation of processes
  • A transformation of the production environment based on paperwork into a digitised process connected to the CEIT Digital Twin Platform

By implementing the CEIT Digital Twin Platform, the client gains:

  • A detailed overview of what is happening in the business via monitoring
  • Advanced planning and management of production and logistics processes
  • Advanced autonomous scheduling of operator actions in real time
  • Advanced autonomous management of logistics technology
  • Connection between planning and management
  • Optimisation of processes via the analysis of business data
  • Reduction in the decision-making process through the availability of relevant business data
  • Prediction and operative planning of machine and equipment maintenance
  • Continual improvement of logistics processes
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