MAST Digital Twin Module: Real-Time Insights for Smarter Manufacturing
Manufacturers are under increasing pressure to optimize operations, predict failures, and improve efficiency—but traditional monitoring systems only provide a limited snapshot of production. Without a dynamic, real-time view of equipment, processes, and systems, companies struggle to make proactive, data-driven decisions.
The MAST Digital Twin Module creates a virtual representation of your production environment, integrating real-time data with advanced analytics to simulate, monitor, and optimize manufacturing performance.
What is the MAST Digital Twin Module?
A Digital Twin is more than just a 3D model—it’s a living, data-driven system that mirrors real-world equipment, processes, and entire production lines. The MAST Digital Twin Module provides:
- Real-Time Data Integration – Syncs with SCADA, PLCs, IoT sensors, MES, and ERP systems to maintain an up-to-date virtual model.
- Process Simulation & Optimization – Test "what-if" scenarios to predict the impact of changes before they happen.
- Predictive Maintenance Insights – Identify potential failures before they cause downtime.
- Performance & Energy Monitoring – Track key metrics like OEE, cycle times, energy consumption, and production bottlenecks.
- AI-Powered Continuous Learning – Uses historical and real-time data to improve forecasting and decision-making.
Proof in Results: Reducing Downtime for an Aerospace Manufacturer
An CPG manufacturer struggled with unplanned downtime and inefficient process adjustments. Without a real-time view of machine performance and process interactions, they relied on reactive maintenance and manual process optimizations.
mode40 deployed the MAST Digital Twin Module, creating a real-time, AI-enhanced model of the production environment. The results?
✅ 40% reduction in unplanned downtime through predictive maintenance insights.
✅ 30% improvement in production efficiency, optimizing scheduling based on digital twin simulations.
✅ Faster troubleshooting, reducing root cause analysis time by 50%.
✅ Optimized energy usage, leading to a 15% decrease in operational costs.
More Than a Model—A Real-Time Intelligence System
The MAST Digital Twin Module is not just a visualization tool—it’s an intelligent system that helps manufacturers predict, prevent, and optimize operations in real time. By leveraging AI, IoT, and real-time analytics, manufacturers gain a true Manufacturing Source of Truth, ensuring continuous improvement and maximum efficiency.
What is your Manufacturing Source of Truth?
About mode40
mode40 is a full-service digital transformation company. We partner with companies looking to advance Industry 4.0 initiatives and drive measurable value across the enterprise through technology adoption. We seamlessly integrate engineering and technology to optimize manufacturing systems. Our mission is to guide clients through their digital transformation journey by aligning people, processes, and technology for maximum profit while solving business problems. We unlock profit from existing processes while engaging the workforce with technology tools while utilizing your current systems and existing assets before investing in new systems. mode40 acts as an extension of your team, or the whole team on digital transformation projects. We position resources for your transformation timeline and accelerate time-to-value to new or active projects.
