Define the representation and its purpose
Depending on the objective, a model may include geometry, process relationships, equipment states or physical behavior. Siemens describes executable digital twins as simulation models that can operate alongside physical assets using operational data. This is a technical possibility rather than a universal requirement. Each industrial application needs a defined scope, level of detail and explanation of the limits of its chosen representation and associated calculations.
Organize the data feeding the model
Integration begins by inventorying available variables, sensors, historical records and asset information sources. Units, asset identification and time references need to be consistent. The model and interface must recognize missing data and invalid readings. Before expanding the project, a pilot application can establish whether existing information supports the proposed question and identify additional measurements that may be necessary, without assuming all required data already exists.
Validate scenarios before using results
Comparison with known observations helps assess a model within a defined operating range. Assumptions and uncertainties should accompany analyses so simulation results are not confused with direct measurements. A change proposed in a digital environment still needs the technical evaluation required for the actual process. Handover should also identify who updates the model when equipment, parameters or operating conditions change, keeping its representation aligned with the installation.
What to assess for your project
- Define the decision and represented asset.
- Inventory data, units and process history.
- Compare the model with known conditions.
- Document assumptions and usage limits.
COM3
How COM3 can help
COM3 can help structure industrial process digital twin projects through needs assessment and integration of available data. Scope can include process representation, supervisory system connections, dashboards and pilot validation, with clear criteria for assessing the usefulness of the model before the application is extended to more assets.
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Further reading and references
Technical sources consulted for the fundamentals of this content. Project recommendations are an editorial synthesis by COM3.