Case Studies
15 min read
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January 15, 2024
Digital Twin Implementation: A 36-Month Retrospective
Quantifiable results from implementing predictive maintenance via digital twin simulations in dye-house operations.
Three years ago we instrumented a complete dye-house — every pump, valve, and heat exchanger — and built its digital twin. This retrospective publishes the numbers.
Predictive maintenance driven by twin simulations cut unplanned downtime by 62% and extended mean component life by 19%. Just as importantly, chemical dosing accuracy improved enough to reduce re-dye rates below 0.8%.
We also document what did not work: the first-generation vibration models produced too many false positives until retrained on six months of local data.
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