#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 ergonomics

Whether 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 twin
• Examples of product vs. process value in different industries
• Planning new factory builds with simulation-first strategies
• Creating human and robot twins for safety and efficiency
• Integrating sustainability into manufacturing process design
• A roadmap for getting started and scaling virtual twin technology

Resources  Contact:
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