Digital Twins: The Shortcut to Smarter Operations

Let’s be honest—when was the last time you used a paper map to plan a cross-country road trip? Probably never (or not since 1999). Yet, that’s exactly what it’s like when manufacturers try to operate without a digital twin.

You’re guessing at the best route. You’re blind to traffic jams. You don’t know what’s around the corner. And if something goes wrong? Good luck finding help fast.

That’s why forward-thinking organizations are tossing the old “map” and upgrading to real-time, dynamic, data-powered digital twins. And with Hexagon’s Digital Twin solution, you don’t just get a GPS—you get mission control.

So… What Is a Digital Twin?

Imagine a living, breathing, real-time digital replica of your plant. Not just a static model or a glorified spreadsheet—but a smart, connected mirror of your facility that updates in real time and learns from your operations.

Gartner defines it as a “software design pattern” (a fancy way of saying blueprint) that reflects your physical asset. But Hexagon takes it further. Their digital twin solutions connect project data, operational data, and real-time insight—creating a single version of the truth you can trust.

With Hexagon, you get two powerful elements:

The Project Twin: Everything from engineering designs to initial asset configuration.
The Operational Twin: Real-time performance, maintenance, safety, and more.
Together, they create a complete picture—past, present, and future.

Why You Need One Yesterday

Here’s a wild stat: IDC predicts the digital universe will hit 175 zettabytes by 2025. That’s a lot of data flying around. Without a strategy to manage it, you’re basically drinking from a firehose.

Hexagon’s digital twin solution helps you:

• Make faster, smarter decisions
• Improve safety and efficiency
• Visualize what’s really happening in your plant
• Predict and prevent problems before they escalate
• Eliminate silos between departments

In short? You’ll know what happened, what’s happening, what could happen, and what should happen—all in one intuitive platform.

Your Four-Step Journey to Digital Twin Greatness

No matter where you are on your digital maturity journey, Hexagon’s got you covered. Here’s how it works:

🔹 Stage 1: Smart Foundations
Start with structured data and docs from your engineering team. It’s like laying the foundation for your digital empire—strong, organized, and ready to grow.

🔹 Stage 2: Visual Connections
Link that data to 2D schematics or 3D models. Want to see your plant like a video game character would? Done. Now you’re not just looking at data—you’re exploring it.

🔹 Stage 3: Intelligent Integration
Plug into your asset performance systems, data historians, maintenance platforms, and real-time feeds. Everything talks to each other, and nothing falls through the cracks.

🔹 Stage 4: Predictive Superpowers
This is where the magic happens. AI, machine learning, predictive maintenance, digital inspections—it’s the full smart factory experience. Your digital twin evolves into a strategic powerhouse.

From Data to Decisions

At the heart of Hexagon’s solution is optimized situational awareness. This means your team isn’t just drowning in data—they actually understand it. With a high-level dashboard that blends real-time insights with historical context, your team can act quickly, confidently, and collaboratively.

Because when operations, safety, maintenance, and engineering all have access to the same living, breathing digital twin? That’s when the sparks of efficiency, innovation, and profitability fly.

The Final Word

Still running your plant like it’s 1999? It’s time to break up with the spreadsheets and dusty filing cabinets.

Hexagon’s digital twin isn’t just a tech trend—it’s the engine behind modern asset management and operational excellence. Whether you’re just getting started or ready to dive into predictive analytics and AI, Hexagon helps you build a digital ecosystem that evolves with your business.

🚀 Design smarter. Operate faster. Decide better.
That’s the power of Hexagon’s digital twin.

Ready to upgrade from paper map to mission control?
Let’s build your digital twin—together.