Manufacturing today faces significant challenges due to a skills shortage exacerbated by the pandemic and an aging workforce.
According to The Manufacturing Institute, 78% of companies are concerned about this issue, and 75% are struggling to fill positions. Research from Visual Components indicates that nearly one in six manufacturing leaders in the UK, US, and Germany expect 41% or more of their workforce could leave within the next five years. Yet, only a third of companies are actively investing in hiring or partnering with educational institutions to build a robust talent pipeline. This shortfall results in higher overtime costs, project delays, reduced profits, and long-term revenue loss, which weakens competitiveness and damages reputations.
To address these issues and enhance factory floor operations, manufacturers need strategies that boost productivity and support workforce re- and upskilling. Digital twins, as well as other digital transformation solutions more broadly, have emerged as a critical solution for tackling these challenges and future-proofing operations.
The power of digital twins in modern manufacturing
A digital twin in the context of manufacturing is a virtual model of a physical system that reflects its real-world counterpart, enabling manufacturers to monitor, test, and optimize operations in real-time. While simulations and digital twins are related, their functions in manufacturing complement each other.
Simulations use software-based models to replicate real-world behaviour, allowing manufacturers to test, train, and make informed decisions about designs or processes in a virtual environment. They are effective for optimizing individual production phases and training employees without affecting actual operations.
Digital twins take this further by representing the full lifecycle of a process or system—from design and operation to modification, commissioning, and decommissioning. Continuously integrating data to reflect current conditions, digital twins offer a real-time model that evolves with its physical counterpart. This capability allows manufacturers to monitor performance, predict future outcomes, identify potential issues, and make data-driven adjustments with minimal risk.
Digital twins also facilitate communication of factory-level changes, helping teams on the factory floor visualise changes, their impacts and adapt before physical implementation takes place.
Supporting workforce development through digital tools
The skills shortage impacting the manufacturing industry requires solutions that not only boost operational efficiency but also support workforce training and upskilling. Robot offline programming (OLP) complements digital twins in this regard by allowing manufacturers to program robots without interrupting ongoing production. This is particularly valuable for ‘high mix, low volume’ environments where flexibility and rapid adaptation are essential.
OLP enables engineers who traditionally rely on handheld teach pendants to program robots remotely using computers. This shift opens opportunities for skilled workers, such as former welders, to transition into new roles as robot programmers who can use this software to plan things like robot weld paths remotely. This training approach aligns with the use of digital twins by providing employees with practical experience in a risk-free virtual setting, enhancing their skill sets without impacting real-world production.
Building a resilient factory floor
With 98% of manufacturers feeling the impact of the skills shortage, addressing this gap through effective training and upskilling has become crucial. Industry surveys reveal that while 87% of organizations prioritize workforce development, many struggle with implementation. Digital twins, simulations, and OLP offer practical pathways for developing skills that empower employees to transition from manual tasks to advanced digital processes.
By working within a digital twin environment, employees gain confidence and discover improvements that can be applied with minimal production downtime. This hands-on experience helps manufacturers build a workforce capable of meeting current and future challenges on the factory floor.
Why investing in digital solutions matters
Investing in digital manufacturing solutions, including digital twins, is not just about staying current; it’s about staying competitive and resilient. These tools provide the means for manufacturers to address workforce shortages, enhance productivity, and future-proof operations. Visual Components, with 25 years of expertise in supporting global organizations, is a trusted partner for companies looking to enhance their operations through digital transformation.
Join us at the Manufacturing Leaders’ Summit
To see firsthand how digital twins and other digital manufacturing solutions can transform your factory floor, join Visual Components at the Manufacturing Leaders’ Summit. Participate in our roundtable discussion to explore the practical applications of these technologies and discover strategies to overcome workforce challenges and optimize operations.
We look forward to connecting with you at the summit!
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