#88: Virtual Twins: Revolutionizing Manufacturing Processes

In this episode of Stay Sharp in Digital Engineering, we go beyond the product digital twin and dive into the transformative world of virtual twins for manufacturing processes. Juliann and Jonathan are joined by Kevin Sullivan of Dassault Systèmes to explore how leading manufacturers are using process twins to simulate, optimize, and future-proof their factory operations.You’ll learn:  ✅ The difference between digital twins and virtual twins  ✅ How process twins drive efficiency, lean manufacturing, and pull-based production  ✅ Real-world use cases from bottling lines to automotive to greenfield factory builds  ✅ Why simulation matters more than ever in high-speed, high-volume production  ✅ How virtual twins support sustainability, supply chain resilience, and even human ergonomicsWhether you’re designing a new facility or trying to modernize an existing one, this episode will give you practical insights on how to use virtual twins to cut costs, reduce risk, and increase adaptability.Topics Discussed:What sets a “virtual twin” apart from a standard digital twinExamples of product vs. process value in different industriesPlanning new factory builds with simulation-first strategiesCreating human and robot twins for safety and efficiencyIntegrating sustainability into manufacturing process designA roadmap for getting started and scaling virtual twin technologyResources  Contact: Have questions or want to connect with our guest? Drop us a line at 📧 [email protected]📌 Don’t forget to like, subscribe, and leave a review on your favorite podcast platform!Music is considered “royalty-free” and discovered on Story Blocks.Technical Podcast Support by Jon Keur at Wayfare Recording Co.© 2026 Razorleaf Corp. All Rights Reserved.