Digital Twin Lifecycle Management
Defining and ranking data fabrics and middleware to guarantee a single source of truth for assets over a 30-year lifecycle, from the design desk to field service.
Client
Global Heavy-Equipment OEM
Objective
Guarantee a Single Source of Truth
Timeline
10-Week Program
Key Focus
Data Integrity & Integration
The Challenge: Maintaining the Digital Thread
A digital twin delivers maximum value only when it stays in lock-step with the real asset across its entire lifecycle. Three major obstacles stall this "digital thread" and prevent universal rollout.
Data Integrity at Scale
Keeping BOM structures, sensor tags, and 3D meshes synchronized between disparate systems like CAD, PLM, and MES over 25+ years is a non-trivial data science challenge.
Heterogeneous Software Stacks
Firms juggle dozens of different enterprise software systems. Building and maintaining the "API glue" to connect them is costly and fragile.
Workforce Upskilling
Without targeted training and intuitive user interfaces, valuable insights from digital twins die in dashboards that legacy teams don't check or understand.
Key Outcomes: Five Lead Platforms for a Unified Lifecycle
Our analysis delivered a shortlist of five platforms that work together to create a seamless, end-to-end digital twin lifecycle.
Graph-Based Data Fabric
Auto-maps tags from PLM to MES to IIoT, ensuring <0.3% data drift after 5 years.
OPC UA + AAS Middleware
Provides 200+ ready connectors and a low-code UI for bridging legacy and modern systems.
Blockchain-Based Version Vault
Creates a tamper-proof audit trail for regulatory compliance and warranty claims.
Mixed-Reality Service Viewer
Overlays live sensor data on 3D CAD via HoloLens, boosting first-time-fix rates by 18%.
Adaptive Training Portal
Drives 82% monthly active user adoption with micro-learning and AR tutorials.
Strategic Impact: A Scalable Template
The OEM green-lit a 20-asset pilot using the graph-data fabric and mixed-reality viewer. The success of this pilot will set a scalable template for decades-long, continuously-synchronized digital twins—bridging design, production, and service while keeping data secure and teams empowered.