Digital Twin

Build virtual replicas of your production facilities. Test layouts, simulate flows, and validate CAPEX decisions — before investing a single euro.

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Simulate Before You Invest

Digital Twin by DBR77 creates fully parametric virtual models of your manufacturing plant — layouts, process flows, material handling, and workforce. Run “what-if” scenarios in hours, not months.

Avoid costly mistakes: our clients have saved up to €7M by identifying the real bottleneck before committing to CAPEX.

Identify Real Bottlenecks

Stop investing in the wrong areas. Digital Twin uses discrete-event simulation with stochastic deviation models derived from your historical data — not ideal-world assumptions.

The platform ranks constraints by actual utilization, queue lengths, and wait times, giving you an objective, data-driven view that every department can agree on.

From Layout to ROI in One Platform

Import CAD floor plans, map process routes, integrate ERP/MES/IoT data, and build your as-is model. Then create to-be scenarios: new lines, automation, layout changes, staffing adjustments.

Every scenario comes with a financial overlay — NPV, payback period, ROI — ready for the investment committee.

90 % Shorter Facility Design Cycle
20 % Efficiency Increase
75 % Faster Change Implementation

Use Cases

Greenfield & Expansion

Design new facilities or major expansions in 3D. Test material flows in motion and validate CAPEX before breaking ground.

Layout Relocation

Plan relocation sequences that maintain production continuity. Validate buffers, transport paths, and minimize downtime.

Intralogistics Optimization

Optimize Milkrun routes, Kanban replenishment, and buffer sizing. Simulate with real-world deviations — scrap, delays, absenteeism.

Warehouse Throughput

Simulate warehouse operations, identify bottlenecks, validate staffing levels. Optimize slotting and pick paths.

Line Balancing

Simulate operator assignments with variability and absenteeism. Find the staffing configuration that maximizes throughput.

Virtual Showroom

For equipment suppliers: interactive 3D demos, VR/AR product presentations, and remote walkthroughs that close deals faster.

Proven Results

€7M Saved in CAPEX

A plant planned a €10M new line for 20% more throughput. Digital Twin revealed the real bottleneck was internal logistics. A €3M targeted investment delivered the same capacity gain.

OEE from 65% to 78%

Digital Twin analyzed failures, micro-stoppages, changeovers, and material logistics — then simulated shift reorganization and buffer redesign. No major CAPEX required.

Analysis Time: Weeks → Days

CAPEX feasibility studies that took 3–6 months are now completed in 4–8 weeks with more scenario variants evaluated.

€15M Investment Avoided

Digital Twin proved that a planned hall expansion wouldn’t deliver proportional benefits. A €2M reorganization achieved the same output on existing floor space.

Frequently Asked Questions

The first calibrated model (as-is) is typically ready within 4–8 weeks. From there, you can run what-if scenarios and receive investment recommendations with financial projections immediately.
Yes. The platform imports CAD floor plans, ERP/MES data, and IoT signals. Every machine, operator, transport route, and buffer is parameterized to match your real-world operations.
Models are calibrated against your historical data until key KPIs match reality within ±5–10%. Stochastic simulations account for variability (breakdowns, absenteeism, demand fluctuations) — so results reflect the real world, not an ideal scenario.
Digital Twin integrates with ERP, MES, WMS, CMMS, SCADA/IoT via CSV/Excel import, REST/GraphQL API, or real-time data streams (MQTT, OPC UA). The platform runs as SaaS — no local servers required.
Absolutely. Most clients start with a single line or production area. The model can then be extended to cover additional lines, halls, or entire facilities — including multi-site deployments.
All data is encrypted in transit (TLS 1.2+) and at rest. Access is controlled via RBAC. The platform is ISO 27001 compliant with data residency options in the EU, US, GCC, and Japan.
Digital Twin is a powerful engine for testing Lean improvements. Simulate SMED projects, 5S impacts, TPM scenarios, and Heijunka variants — then measure the system-wide effect before implementation on the shop floor.
Typical 5-year ROI exceeds 150%. Payback periods of 1–2 years are common, driven by avoided over-investment, higher throughput, and reduced WIP. The platform generates detailed ROI reports for your investment committee.

See Your Plant in Digital

Book a personalized walkthrough and discover how Digital Twin can de-risk your next CAPEX decision.

Schedule a Demo