Challenges of Digital Twin Application in Manufacturing

The term Digital Twin (DT) is highly prevalent in manufacturing organizations and academic research. A DT is a virtual representation of a physical entity that mirrors its states and properties. According to common definitions, a true DT has the ability to change its physical entity. In practice, however, implementations are often only subcategories, such as Digital Models (DM) or Digital Shadows (DS). The maturity level of claimed implementations varies among different sectors in manufacturing. This article uses the aerospace and automotive industries as examples to highlight challenges that prevent the DT from widespread use. Based on 21 expert interviews with representatives from senior executives to lower management from 9 different companies, consisting of aerospace and automotive OEMs and top management consulting firms, a qualitative content analysis (QCA) was conducted. As a result, 15 main challenges to the application of DTs were identified and grouped into 3 clusters: technical, organizational, and methodological. The findings emphasize the importance of human factors and adequate change management. Ultimately, 4 measures were extracted that help to overcome these challenges and increase effectiveness of DT application.