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August 4, 2025 17 mins

Unlock the transformative power of virtual prototyping in manufacturing with this deep dive into digital twin technology. Moving beyond traditional approaches that rely on costly physical testing and time-consuming troubleshooting, digital twins offer a revolutionary alternative that's changing how industrial facilities design, validate, and optimize their operations.

What exactly is a digital twin? Far more than just a marketing animation, these sophisticated virtual models precisely mirror physical systems using actual control code and HMIs to create functional replicas that behave exactly like their real-world counterparts. This allows manufacturers to simulate entire production lines before spending a single dollar on equipment, identifying bottlenecks and inefficiencies at the design stage rather than after installation when changes become exponentially more expensive.

The benefits extend well beyond design validation. Digital twins dramatically reduce risk by eliminating potential material damage or machinery breakdowns during testing. They're particularly valuable in highly regulated industries like pharmaceuticals where errors can damage reputations or ruin production batches. They also revolutionize operator training, allowing staff to learn in safe virtual environments using real-world operating screens before encountering potentially dangerous equipment on the plant floor. Though typically achieving 80-90% accuracy (no simulation can perfectly replicate every nuance), this technology delivers enormous time and cost savings compared to traditional methods.

Ready to explore how digital twins could transform your operations? Connect with the experts at Electrical Equipment Company through our labs where you can experience this technology firsthand. Schedule a visit through the links in our show notes and discover how the right partnerships can help you leverage virtual prototyping to design, build, and operate with superior efficiency in today's competitive manufacturing landscape.

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Read our latest article on Industrial Manufacturing here
https://eecoonline.com/inspire/virtual_prototype


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Host: Chris Grainger

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Episode Transcript

Available transcripts are automatically generated. Complete accuracy is not guaranteed.
Speaker 1 (00:00):
Welcome to Eco Ask why, a podcast that dives into
industrial manufacturing topicsand spotlights the heroes that
keep America running.
I'm your host, chris Granger,and on this podcast we do not
cover the latest features andbenefits on products that come
to market.
Instead, we focus on advice andinsight from the top minds of
industry, because people andideas will be how America

(00:24):
remains number one inmanufacturing in the world.
Welcome to Eco Asks why.
I'm your host, chris Granger,looking forward to hanging out
with you today.
Thank you so much for listening.
We're going to be continuing totalk about this industrial
manufacturing focus that we'rereally trying to just bring some
insights to you on somedifferent things that are

(00:46):
happening out there in theindustrial manufacturing world.
Last month we talked a lotabout the skills gap and that we
recognize it's a majoropportunity, it's not a hurdle,
it's an opportunity and how toaddress that.
So if you haven't listened tothat, I encourage you to go back
, check out that last episode inyour podcast feed and hopefully
you'll enjoy that.

(01:06):
All right, so today for this,we're going to get a little
technical we're looking for I'mreally looking forward to this
one.
We're going to be talking aboutthe power of virtual
prototyping.
Okay, you may heard referred toas industrial twins and the
digital twins, rather and howthat is revolutionizing
operations in industrialmanufacturing, and we understand

(01:28):
at ECO the critical challengesthat modern industrial
manufacturing chains are facingeach and every day.
You have challenges likeoptimizing complex operations to
accelerating project timelines,and you need to do all this
while trying to maintain a veryrobust return on investment

(01:49):
right, and businesses areconstantly seeking innovative
solutions to get an edge.
So, as we're starting to reallydive deep into this evolving
landscape of industrialmanufacturing, we're going to be
talking about right here howdigital twin technology could be
something you could leverage inyour process and in your

(02:10):
facility, because our value atECO extends beyond just supply.
We specialize in reallyconnecting you the listeners,
the people who we serve with theright technology partners to
bring your digitaltransformation goals to life,
and digital twins are a majorstep in that direction.

(02:33):
So we fully believe that,embracing this transformative
approach, the market that welove, the industrial market, can
unlock unprecedented levels ofefficiency and operational
success, and that's just goingto be a win for everybody across
the board.

(02:53):
So, at the core, a digital twinis not merely just some animated
or static visual representation.
It's a controlled simulation.
Really, that's what it.
It's a controlled simulation.
Really, that's what it is.
A controlled simulation, it's adynamic virtual model that
precisely mirrors the physicalsystem, the process, or it could

(03:15):
be even the entire facility.
It's crazy with the technologythat's out there right now.
So this is not like a simpleanimation for marketing or to
try to get clicks on a LinkedInpage.
That's not what this is.
These are purpose built forabsolute rigorous testing and

(03:36):
validation of a design beforemanufacturing of that equipment,
of that equipment okay, andthat's a very distinct piece of
information that we need tounderstand, because this is
active.
This is a functional replicaand it's designed to behave
exactly as the physicalcounterpart would.
So just think about, for example, the complexity of a modern

(04:00):
manufacturing line.
If you have been to a modern,most of us are in manufacturing.
But if you haven't been to amodern manufacturing line, if
you have been to a modern, mostof us are in manufacturing, but
if you haven't been to a modernmanufacturing plant, I encourage
you to go line up a tour andconsider one like a beverage
production facility high speedokay, they were doing 700 cans a
minute.
Traditionally, designing,building and optimizing such a

(04:23):
line involved a lot of physicalprototyping.
I mean a lot of prototyping.
So you had extensive on-sitetroubleshooting.
Then you had some things wenttoo far south.
You had some costly adjustmentsafter that commissioning
process and this could takequite a bit of time.
This could take days, weeks,months, and this could take

(04:45):
quite a bit of time.
This could take days, weeks,months.
And every time that you'redelaying, you're delaying
production and you're erodingprofitability, and that's a big
deal in business.
We have to do all we can tomaintain that competitive edge.
So the digital twin technologygives you a powerful alternative
.
Okay, gives you a powerfulalternative.
Okay, you can use your originalcontrol code and HMIs or

(05:08):
human-machine interfaces, right,and a digital twin can
accurately model the mechanicaland operational sides of a
system in a virtual environment.
So this means the exactapplication code that you're
going to be using in the fieldfor every machine, for every

(05:31):
conveyor system, for every speed, position, valve, contact point
is simulated directly insidethe digital twin.
Huge difference, right, and theimmediate and most significant
benefit of this controlsimulation is your ability to
optimize operation andaccelerate those project
timelines.
So just think about it for asecond Before a single piece of

(05:52):
equipment is ever manufacturedor procured or installed.
You, at the plant level, canrun extensive simulations to
find out what the potentialbottlenecks with the proposed
line could be.
And this capability to to runthese extensive simulations will

(06:15):
give you the opportunity to toidentify the inefficiencies at
the design stage.
And that's revolutionary,because you don't want to find
this stuff out once it's thereand it's in operation.
Man, at that point you're justyou're putting band-aids, you're
just you're having to react.
But the digital twin gives youthat, that opportunity to adjust

(06:36):
, you make some speed,optimization and changes to see,
okay, what if I, if I do this,do this here, what's the impact
there?
And this can be done relativelyquickly so we can really have a
dramatic impact and return oninvestment directly for the

(06:56):
project, for manufacturers, sofor companies like HECO.
This means we're here to guideyou and help you towards
solutions that deploy thesesystems faster and start
generating revenue sooner.
It's all about helping you becompetitive in the market.

(07:17):
That's what we want you toimplement strategies at work.

(07:40):
That's what it's all about atthe end of the day and that's
the level of commitment that wehave to serving you.
And, furthermore, this digitaltwin technology is an invaluable
tool for risk mitigation, aswell as that equipment
validation, because, think aboutit, the traditional way of

(08:01):
testing involves very real riskof breaking either material or
damaging machinery.
Right, it's just there.
You have to try some things atsome points, but in that virtual
environment these are alleliminated.
Because this is critical, forif you're in an industry that's

(08:21):
highly regulated so I'm thinkinglike pharmaceuticals out there
for you, those that are in thatindustry where you know a single
error can ruin your reputationor a major batch.
If you have something wrongwith a batch of product, it has
severe consequences.
And you have to leveragedigital twins, and particularly

(08:45):
in that industry, to simulatethe behavior of a complex
process skids with thesedifferent types of interfaces,
and this helps you qualify andvalidate your equipment and your
processes and your changesbefore they're ever introduced
in a real-life environment.
And this validation helps Justthink about it practically it

(09:08):
ensures that all your interlocks, all your operational pieces,
everything functions correctly,and it safeguards your product
quality as well as the peoplewho are going to use your
product the patients and theirsafety.
So it's a big deal.
So one thing to consider withthis digital twin technology the
patients and their safety.
So it's a big deal.
One thing to consider with thisdigital twin technology beyond

(09:31):
design and validation, we getthat that's important, but think
about operator training as well.
So instead of having anoperator learn on an expensive
and potentially dangerous pieceof equipment, okay, you can take
new and existing operators andtrain them in a safe virtual
environment.
So this means that theseoperators are interacting with

(09:56):
real-world operating screens,like these HMIs that we've
already talked about, and seeingthe physical equipment views
that replicate what they'regoing to be encountering when
they're on the plant floor.
And this type of trainingallows them to really dive deep
and to get in to understand thedifferent types of operational

(10:16):
schemes and the different typesof things that can happen on the
floor.
This also helps them respond tosome faults.
So you would purposelyintroduce faults and see how
they respond to it, and as theylearn this, what's happening?
They're becoming more and moreproficient with the system.
Before they actually get to theproduction line to go from one

(10:40):
machine to another.
It gives you so much moreopportunity to do this
effectively and avoid hazards.
Right, just because you putthis in place, and this really
is going to equate to a betterprepared staff, you're going to
have less human error.

(11:00):
It's going to have smootheroperations from day one.
So this really aims.
This technology is really.
It's awesome.
And I want to put a caveat outthere, because I know I've
pumped this thing up pretty good.
But here's your caveat.
Okay, because there's no suchthing as it can't always be
gravy baby, there's usuallysomething else right.

(11:21):
There is no perfect digitaltwin, there's usually something
else right.
There is no perfect digitaltwin because the goal can't be
to simulate every bolt and chainand every little nuanced thing
that can happen, but the goal,rather, is to provide an overall
view on how the system is goingto operate.
Ok, so think about typically, adigital twin will help you

(11:44):
achieve 80 to 90 percentaccuracy.
That's still huge.
Think about it 80% or 90%accuracy before anything ever
gets installed.
So you still have a percentageof validation when the equipment
gets there and optimization tofine-tune to complete that

(12:04):
physical system once it's built.
But this still offers anenormous time and cost-saving
approach compared to thosetraditional methods that are out
there.
And again, for eco, this verysimply means helping you set the
right expectations whiledelivering exceptional value in
those performance gains.

(12:25):
So, as we kind of wrap up thistalk around digital twins, they
really give us a monumental leapforward in industrial
manufacturing.
It's incredible what'shappening out there.
It's empowering companies tosimulate their facility before
spending any significant moneyor doing physical

(12:48):
troubleshooting.
It offers a controlledenvironment for that design
validation.
Just think about a safe spaceto validate.
Try, you can crash it, you'renot going to hurt anything.
It creates operationaloptimization so you can learn as
you go on.
What are the things that we needto change in our operations to
truly optimize and to improvethe process.
We're lowering the risk for ouremployees, the people that are

(13:12):
working with the equipmentbecause we can identify oh, that
should not happen.
Let's figure out we should havethose oh that should not be
happening moments in a simulatedenvironment.
Then we can fix it and also,all along the way, have chances
to train our operators at ahigher level.
And, from our standpoint hereat Electrical Equipment Company,

(13:34):
we want to champion thesedifferent types of digital twins
and help ultimately with ourmission, which is to bring
together the right solutions,the right partners and the right
expertise so that you canthrive in this complex and very
competitive world that's outthere.
So this is a very powerfulvirtual prototyping tool that we

(13:57):
just wanted to make you awareof and it's not going to help
you overcome every challenge,but it's definitely going to
help you become more resilientan opportunity to be more
optimized and really futureready as you start looking at
your changing landscape andmanufacturing.
So we encourage you to embraceit.
Embrace the digital twintechnology, because it's not

(14:20):
just a new tool.
It's really about thepartnerships to get the right
people to help transform how youdesign, build and operate for
superior operational success.
Design, build and operate forsuperior operational success.
So that was hopefullyencouraging to you.
If you have questions aboutdigital twins and what that
would look like for differentmanufacturers, again, if you're

(14:42):
in our eco footprint, we wouldabsolutely love to hear from you
and have the conversation.
We have the cool part about it.
It's experts in every area thatwe serve and these experts can
come in and they can have a verydetailed conversation with you,
get down to the brass tacklevel to understand what are
your goals, what is theequipment that you're working

(15:04):
with, what are the lines thatyou have, what are the headwinds
and the hurdles that you'retrying to manage, what future
projects are out there inexpansion things that are six
months, 12 months, 24 months, 36months out in the future to
help you stay ahead.
That's what we're all about,and we have just again a

(15:24):
wonderful team of experts onstaff ready to come in have
these conversations.
Even if they're difficult toget down to the nitty gritty,
we're here and we're ready toserve and that's what it's all
about.
So if you know someone out therewho you think would enjoy
learning a little bit aboutDigital Twins, share this

(15:46):
podcast out with them.
Just hit the share button, sendit right over to them.
Thank you for listening.
If you mind, give us a ratingand review that would be awesome
and just connect with us.
In our show notes we'll havelinks so that you can connect
with us directly.
We'll also have a link to ablog directly on Digital Twin
and we'll have someopportunities for you to connect
.

(16:06):
The best way, really, if youwant to try to start simulating
some of this and start havingconversations, we have labs at
Electrical Equipment Company inall the areas that we cover.
So we have labs where you cancome in and build some of this
equipment directly or simulatesome of it rather with our
technology.
So maybe this is something youjust want to kind of dip your

(16:28):
toe in the water?
Hey, we get it.
That's why we built our labs.
We love for you to connect.
We'll put a link in there aswell where you can actually
schedule time directly to comeinto our labs, engage and have a
little bit of fun, because whosays manufacturing can't be fun?
It is absolutely a ton of funout there, particularly when you
start playing with technologylike this.
So thank you again for listening.
Hopefully you found thisencouraging.

(16:49):
Again, give us a rating andreview, share this out with
others and hopefully we'll seeyou next month.
So have a great day andremember to keep asking why.
Thank you for listening to.
Eeco Asks why this show issupported ad-free by Electrical
Equipment Company.
Eeco is redefining theexpectations of an electrical

(17:10):
distributor by placing peopleand ideas before products.
Please subscribe and share withyour colleagues and friends.
Also leave comments, feedbackand any new topics that you
would like to hear.
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