The Industrial Internet of Things (IIoT) and digital twins were treated as a technological curiosity only a few years ago – today they are becoming one of the cornerstones of modern manufacturing. It is no longer a question of whether to implement them, but how quickly. They facilitate process simulation, precise production planning, reduce downtime and support the fight against counterfeiting. Their importance is growing with the expansion of 5G and campus networks built by large industrial companies. Their scalability and readiness to integrate with the rest of the IT infrastructure make them not only transformational tools but also strategic assets for companies.
IIoT – the foundation of digital operations
At the core of the digital twins is the IoT – a dense network of physical devices and machines equipped with sensors that constantly collect data and transmit it in real time. This is data from production, logistics, material consumption and even transport conditions. In an industry that is becoming increasingly complex and costly, this constant digital observation is becoming the starting point for transformation.
IoT is no longer just monitoring, but a layer of infrastructure on which to build complex simulations and decision-making processes. Combined with AI and edge computing, it is becoming less dependent on central server rooms and public clouds and more autonomous – crucial for industries where response times are measured in milliseconds.
The digital twin, or risk-free modelling
A digital twin is a digital copy of a physical object, a production line or an entire process. However, it is not a 3D visualisation, but a realistic, dynamic model fed by sensor data. In it, changes can be tested, failures can be predicted, upgrades can be planned – without interrupting actual production.
The added value is not only in optimising performance, but also in planning predictive maintenance. Instead of scheduling maintenance at regular intervals, companies analyse actual wear and tear and perform maintenance when it is really needed. The result: less unplanned downtime, higher machine availability and savings.
Intralogistics and supply chain – digital transparency
Where previously paperwork and partial automation dominated, today full visibility is emerging. Thanks to IoT and digital twins, it is possible to track the flow of materials within manufacturing plants, including forklift idle times, real-time availability of raw materials or identifying so-called dead zones that limit throughput. The same applies to supply chains – companies can monitor not only the status of a shipment, but also its transport conditions, such as temperature and humidity, crucial for pharmaceuticals or electronics.
A response to counterfeiting and theft
Counterfeit parts, especially in the automotive and aerospace industries, are a real threat to the safety and reputation of manufacturers. By using digital identifiers and linking physical components to their twins, it becomes possible to precisely trace the origin of each part. This makes it possible to detect counterfeits, close the grey market and facilitate complaint processes and audits.
In an industrial setting, the digital twin is therefore not just about optimisation, but also a tool for compliance and safeguarding the interests of the company – crucial especially at a time when supply chains span several continents.
Sustainable transformation without empty declarations
Digitalisation in industry is increasingly having to prove its compatibility with sustainability goals. IoT and digital twins offer concrete value: accurate planning of energy and material consumption, faster product iterations without the need for physical prototypes, better use of machines. In the context of ESG, this is a strong argument that is not based on marketing, but on hard data.
McKinsey estimates that the use of digital twins can increase sales by up to 10%, reduce time to market by 50% and improve quality by 25%. Combined with cost pressures and a shortage of skilled labour, these figures are no longer just a promise – they are becoming a market requirement.
From digital experiment to industry standard
IoT and digital twins are rapidly moving out of the ‘proof of concept’ phase and into the core of operational strategies. This trend is particularly evident in high-cost countries, where inefficiency is not only a problem but often a barrier to competitiveness. The shift is being driven by the availability of 5G, edge computing and more flexible deployment models, including campus networks and private clouds.
Today’s manufacturing environment doesn’t need any more sensors. It needs smarter data, better simulations and faster decisions. IIoT and digital twins are not just supporting technology today – they are the infrastructure of the future.
