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Digital twinning is no longer just a futuristic concept. It's becoming a practical tool for businesses seeking greater visibility..

Digital Twins: A Practical Tool for Modern Supply Chains

Digital twinning is no longer just a futuristic concept. It’s becoming a practical tool for businesses seeking greater visibility, efficiency, and resilience in their supply chains.Simply put, a digital twin is a virtual replica of a physical process, product, or system. These replicas use real-time data from sensors, IoT devices, and other sources to mirror what’s happening in the real world.

In supply chains, where even minor disruptions can ripple across the entire operation, digital twins are proving invaluable. By enabling companies to monitor their operations in real-time, test scenarios, and predict outcomes, this technology is helping businesses stay agile and competitive, mitigating huge profit losses caused by supply chain issues

 

How Simulations Improve Supply Chains

Supply chains are complex networks, often spanning multiple geographies and involving numerous stakeholders. Digital twins provide a centralised view of these networks, enabling decision-makers to pinpoint inefficiencies and identify risks.

For example, a digital twin of a warehouse can track inventory in real-time, predict when stock will run low, and suggest optimised replenishment schedules. Similarly, a digital twin of a transport network can identify potential bottlenecks, such as traffic congestion or port delays, and recommend alternative routes.

According to Gartner, by 2026, 75% of organisations that use Internet of Things (IoT) technology will have implemented some form of digital twin. Early adopters report benefits like improved operational efficiency, reduced downtime, and better forecasting accuracy.

 

Using Simulations to Manage Risk

One of the most powerful applications of digital twins is their ability to simulate various scenarios. Simulations allow businesses to model the impact of potential disruptions, such as natural disasters, supply shortages, or geopolitical tensions. Take, for example, the COVID-19 pandemic, which exposed vulnerabilities in global supply chains. Companies with digital twin technology were better equipped to respond to sudden shifts in demand and disruptions to supply. By running “what if” scenarios, businesses can understand the likely outcomes of specific events and create contingency plans in advance.

Simulations can also help optimise operations under normal circumstances. For instance, a retailer can test different promotional strategies within a virtual environment to see how changes in demand will affect inventory.

The combination of digital twins and advanced simulation techniques is creating a future where supply chains are not only more efficient but also more resilient. With climate change, geopolitical uncertainty, and evolving customer demands, having the ability to adapt quickly is no longer a luxury—it’s a necessity.

This technology is particularly promising for industries like manufacturing, retail, and healthcare, where supply chain disruptions can have significant consequences. For example, a pharmaceutical company can use a digital twin to model its entire supply chain, ensuring critical medicines are delivered on time, even during a crisis.

 

A Balanced Approach

While the benefits of digital twins are compelling, businesses need to take a measured approach to implementation. Creating and maintaining digital twins requires investment in technology, data integration, and skilled personnel. Companies should start with high-impact use cases, such as inventory management or transportation optimisation, before expanding to more complex applications.

Ultimately, digital twinning is not a silver bullet, but it is a powerful tool when used strategically. By combining digital twins with simulation techniques, businesses can gain a deeper understanding of their operations, mitigate risks, and position themselves for long-term success in a rapidly changing world.

 

Conclusion

Digital twins are not just transforming supply chains—they are helping businesses think ahead. As adoption grows and the technology matures, we can expect digital twins to become a cornerstone of supply chain strategy, enabling companies to navigate uncertainty with confidence. With the right planning and investment, digital twins offer a practical pathway to a more resilient and efficient future.

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