Digital Twin
From concept to operational value — safely, quickly, and at scale
Digital Twins that deliver operational impact
Smarter decisions, lower risk, and higher throughput - MTC’s Digital Twin experts connect your physical operations to a flexible digital world so you can predict, optimise, and control with confidence. A digital twin is a digital replica of assets and processes that exist in the physical world with connectivity between the two. By collecting data from the physical asset, analysing data with the help of models and simulations, and feeding back actionable information, digital twins can drive resource efficiencies in the physical world.
Whether you’re starting with a supervisory twin to unify and visualise live data, advancing to a predictive twin to forecast issues and optimise schedules, or closing the loop with an interactive twin that recommends, or safely automates action on the shop floor, we’ll help you move beyond pilots to operational value.
Our capability
Choose the right Digital Twin for your challenge
Supervisory
Monitor & visualise live data for insight
A Supervisory Digital Twin gives you a trusted, right‑time view of your assets, lines or whole facility by collecting, contextualising and visualising operational data in one place. Operators and leaders see the same KPIs, trends and alerts, so issues are spotted sooner and decisions are made faster.
The practical benefits show up quickly: less time spent hunting for information or building manual reports, clearer accountability across shifts, reduced unplanned downtime and energy or material waste, and a stronger basis for continuous improvement. Just as importantly, this creates the scalable data foundation you need to progress to Predictive and, ultimately, closed‑loop Interactive twins.
Predictive
Forecast, warn early, and optimise schedules
A Predictive Digital Twin looks ahead. By combining live and historical data with models and AI, it forecasts bottlenecks and quality risks, triggers early warnings and runs “what‑if” scenarios to recommend the best plan under real‑world constraints. Teams move from reacting to anticipating, balancing throughput, inventory, changeovers and resources with evidence rather than instinct.
The result is measurable operational lift-shorter changeovers, faster processes, higher first‑pass yield, lower inventory and better on‑time delivery—delivered in a way that’s explainable to users and embedded into daily management routines. Predictive twins also de‑risk bigger changes by proving outcomes virtually before you commit on the shop floor.
Interactive
Recommend or automate control in the real world
An Interactive Digital Twin closes the loop by turning insight into action. It guides operators with clear, context‑aware recommendations—or safely writes back to your MES/SCADA/PLC to adjust set‑points, schedules and workflows automatically where appropriate. Built with governance, cyber security and change management from day one, it delivers consistent, rapid responses to disturbances, reduces stoppages and stabilises quality at scale. You gain a reliable way to institutionalise best practice, cut time‑to‑decision from minutes to seconds, and sustain improvements long after the project team steps back.
Because control is transparent and auditable, confidence grows and so does the return on your Digital Twin investment.
Success stories
Get a feel for how a Digital Twin can benefit your business by reading a few of the successes MTC have had over the past few years.
Thermal Manufacturing Digital Twin: Smarter, Faster, Safer Pharma Packaging
Pharmaceutical blister pack production faces challenges from conservative heating and cooling times, which cause unnecessary delays and risk product quality. MTC’s solution uses live sensor data and real-time simulation models to adaptively predict product temperatures and optimise process operation times. This approach shortens changeover periods, speeds up manufacturing, and ensures consistent, high-quality output.
- 5% faster processing time
- 23% shorter changeover time
- 100% first pass yield
Factory Digital Twin: Unlocking Efficiency and Continuous Improvement
Factories are complex environments with multiple processes requiring constant fine-tuning to avoid disruption and maximise efficiency. MTC’s Factory Digital Twin creates an integrated virtual representation of the physical facility, synchronising live data from processes and systems. This enables root-cause analysis, advanced reporting, and actionable insights, helping stakeholders optimise operations, minimise downtime, and drive higher returns on continuous improvement investments.
- 8% higher operational efficiency
- 11% extra capacity utilisation
- 5% increased CI ROI
Adaptive Scheduling Digital Twin: Streamlining Manufacturing for On-Time Delivery
Manufacturers struggle with unforeseen delays, excess inventory, and inefficient changeovers that disrupt schedules and impact delivery. MTC’s adaptive scheduling digital twin integrates live monitoring of manufacturing, maintenance, and supply chain activities. It automatically detects delays, assesses their impact, and regenerates optimal schedules—reducing inventory, minimising downtime, and improving on-time order completion.
- 12% less downtime
- 9% less inventory
- 21% improved on-time delivery
Our approach
A proven path from idea to live Digital Twin
- Digital Twin discovery
- Architecture & Proof‑of‑Concept
- Prototype to operational
- Design for operations from day one
- Prove & scale (test before rollout, then replicate with confidence)
Digital Twin discovery
We start by aligning stakeholders around a clear problem statement, measurable KPIs and a realistic business case. Through focused workshops and a rapid data audit, we prioritise the most valuable use cases, identify constraints (people, process, data, technology) and map the minimum viable twin that can prove value quickly. The output is a concise discovery pack—use‑case definition, KPI set, value model, data sources, and a phased roadmap—that sets expectations and removes ambiguity before any build begins.
How a Digital Twin could help you
I am a growing midsize company, and I want to digitalise as I grow, but I don’t know where the value is for me.
Digital Twin Discovery
- Current state assessment
- Use case identification
- Knowledge transfer
Output: Practical and high impact use cases, with business case
Impact: Intelligent Customer and future cost reduction
I am a large company collecting a lot of data from my systems, but they are not interconnected. I need a roadmap and architecture.
Digital Twin Architecture and POC
- System analysis and gaps
- System replacement value
- Future architecture
Output: 5 year roadmap, and destination
architecture.
Impact: Derisking Investment and Future Proofing
I have a new or existing critical model for my business, but it runs reactively. I need to transform it into a live digital twin.
Digital Twin Prototype
- Deployment architecture
- Derisking and demonstration
- Adoption into production
Output: Oven-ready digital twin for model, with deployment plan in place
Impact: Demonstratable Benefits
Explore our digital capability
Digital Twins are just one element of our Digital Manufacturing offering. We deliver cutting-edge solutions including digital twinning, automation, and data-driven technologies to help businesses innovate securely and efficiently. Explore how our expertise can transform your operations, boost resilience, and unlock new opportunities for growth below.
A trusted partner
With over 6 years’ experience delivering operational Digital Twins across six sectors, MTC combines deep technical expertise with independent, supplier-agnostic advice. We’ve helped manufacturers achieve measurable gains - like 23% faster changeovers and 21% better on-time delivery - by designing, building and scaling Digital Twins that work in the real world. Our end-to-end approach, standards alignment, and focus on secure, future-proof solutions make us the partner you can rely on to deliver lasting value.
FAQs
What is a digital twin?
A digital twin is a digital replica of assets and processes that exist in the physical world with connectivity between the two. By collecting data from the physical asset, analysing data with the help of models and simulations, and feeding back actionable information, digital twins can drive resource efficiencies in the physical world.
