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What Is A Digital Thread

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Digital twin vs. digital thread: Two


complementary ways to digitally
replicate assets
29 June 2023
3 min read
 What are digital twins?
 What is a digital thread?
 What distinguishes digital twins from digital threads?
 Benefits of digital twins vs. digital thread
 Leverage IBM Maximo Application Suite for your digital transformation
As the pace of digital transformation accelerates in the manufacturing and
engineering industries, two concepts have gained significant traction: digital
twins and digital threads. Both concepts refer to digital representations of
physical objects, but they serve different purposes and offer companies
unique advantages. Here, we will compare digital twins and digital threads,
and discuss potential use cases and benefits.
What are digital twins?
A digital twin is a digital replica of a physical object or system, complete with
all the design and operational data of the physical object, including
geometry, performance data and behavior models. The purpose of a digital
twin is to simulate the behavior of equipment in real-time, allowing
engineers and operators to monitor performance and identify system
issues/anomalies.

Digital twin technology uses Industrial Internet of Things (IIoT)


sensors, machine learning and simulation software to collect product data
and generate accurate models. Teams can then use the models to predict
maintenance needs, simulate changes to the system and optimize processes
(e.g., safety protocols, reporting procedures, manufacturing processes, etc.).

For example, a digital twin of a wind turbine can simulate the impact of
changing wind speed and direction on the turbine’s performance, helping
operators make informed decisions about maintenance and energy
production.
What is a digital thread?
A digital thread is a digital representation of a product’s lifecycle, from
design to manufacturing to maintenance and beyond, providing a seamless
flow of data that connects all aspects of the lifecycle. The purpose of a digital
thread is to provide a complete and transparent view of manufacturing
systems, enabling efficient collaboration and decision-making across all
stages of the process.

Digital threads use a variety of technologies, including computer-aided


design (CAD) software, product lifecycle management (PLM) systems
and Internet of Things (IoT) sensors, to collect and share data
across workflows. Digital thread technology optimizes traceability, providing
a way to track asset progress and ensure that all stakeholders are on the
same page throughout the production process. For example, aerospace
companies can create a digital thread to help assemble aircraft with digital
engineering. Production teams utilize 3D-model-based systems to guarantee
that aircraft are built exactly to engineering specifications and rely on the
digital thread to track progress and identify issues and inefficiencies during
production.
What distinguishes digital twins from digital
threads?
Both digital twins and digital threads utilize virtual representations of real-
world assets and processes, but they offer distinct capabilities.

Scale

Digital twins are scalable, but only to a point. Digital twin technology collects
real-time data from a single source/asset. And although a digital twin
concept can connect to other twins to simulate entire digital environments,
they are most useful in evaluating a specific production environment. A
digital thread concept, on the other hand, is limitlessly scalable. Digital
threads can connect to (almost) any other enterprise system, including
digital twins.

As such, digital thread technology may be best suited for operations and/or
circumstances where data must be gathered from an array of departments,
devices, systems and processes. On the contrary, digital twins will better
serve operations that rely primarily on repetitive machine processes within a
specific production environment.

Data centralization
Both digital twins and digital threads centralize data to some extent. Both
collect comprehensive sensor data and aggregate and store that data in an
easily accessible data hub. However, digital threads enable teams to take
data from digital twins and other sources and centralize the data flow across
departments and production silos so that the entire company can access the
same information. Data attached to a digital thread also tends to be more
consistently accurate, because the automation features of a digital thread
concept eliminate the need to manually transmit information between
departments and workflows.
Benefits of digital twins vs. digital thread
Digital twins and digital threads help organizations increase system
efficiency, reduce production costs, improve product design and limit system
downtime. However, the impact of each technology will vary depending on
manufacturer needs.

Digital twins allow manufacturers to do the following:

 Engage in responsive monitoring in real time


 Conduct proactive risk assessments and utilize predictive
troubleshooting for organizational assets
 Accelerate innovation using digital models and digital mirroring

Digital threads help manufacturers in the following ways:


 Build more agile operations by facilitating a continuous, synchronized
data flow
 Increase interdepartmental collaboration across assets and systems
 Optimize connectivity between manufacturing and engineering
processes
 Streamline product development to reduce production time and get
products to market faster
 Ensure regulatory compliance by tracking the entire product lifecycle,
including design decisions, engineering changes and maintenance
records
Leverage IBM Maximo Application Suite for your
digital transformation
Digital twins and digital threads are essential tools for companies looking to
start or accelerate a digital transformation. Using advanced technological
tools like IBM Maximo can help organizations get there faster.

IBM Maximo is a comprehensive enterprise asset management system that


helps organizations optimize asset performance and streamline day-to-day
operations. Using an integrated AI-powered, cloud-based platform, IBM
Maximo offers comprehensive CMMS capabilities that produce advanced
data analytics and support manufacturers looking to make informed
decisions about system performance and optimization.

Using IBM Maximo software—especially as a complement to existing


enterprise resource management (ERP) systems or a manufacturing
execution system (MES)—can help your facility gain a competitive edge in
today’s ever-evolving manufacturing marketplace.

Author
Chrystal R. China
Writer
Explore how digital twins can optimize the performance of your assets in a
sustainable way
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