Best Practice

DTWIN: your digital companion for manufacturing

The framework for Industrial Digital Twin.

IoT and Digital Twin

The future of process monitoring and Industrial IoT applications is tightly connected to the concept of Digital Twins, a new way of thinking about and implementing distributed systems capable of controlling and anticipating deviations. Digital Twins are an emerging technology that promises to change the existing scenario in many industrial sectors, as well as representing an important element in enabling digital transformation.

Digital simulators

The digital twin is the virtual representation of a machine or physical process. Digital twins are the evolution of digital simulators and as such they start from a simple or complex digital model of a physical or virtual entity, or system of systems. The Digital Twin goes beyond simulation because it can be run in parallel to the real system, in real time, becoming a living digital reference that is continuously fed by the same data that the real system receives and continuously validated by the same outputs that the system produces.

The DTWIN by Concept Reply

Concept Reply created the DTWIN framework to support the rapid development of Digital Twin solutions connected to the physical world. This is thanks to Edge IoT devices from which the Digital Twins extract process information, interfacing directly with machine tools and production systems. The process logic is easily transferred to the Digital Twin, using a virtual representation integrated with Eclipse Vorto Eclipse Vorto ed Eclipse Ditto. These enable the creation of behavioural, business, logistics and intra-logistics models, as well as incorporating neural networks such as classifiers and automatic anomaly analysers. These enable the creation of behavioural, business, logistics and intra-logistics models, as well as incorporating neural networks such as classifiers and automatic anomaly analysers.

The framework DTWIN for Industry

Each Digital Twin is made up of software that executes the model interconnected with the data collected in real time from the production lines, from staff and from the warehouses. This Digital Twin sends its control data and any anomalies it comes across to a display application consisting of a dashboard on a PC, tablet or smartphone, depending on the specific requirements. Together with the real-time monitoring data and immediate warnings, the Digital Twin displays any “future events” which it determines might occur in the short, medium and medium-long term. The model is able to self-train and to adapt to changes in the company set-up without requiring extensive system reconfigurations.


A real case: DTWIN in the Intra-logistics space

Concept Reply has developed a Digital Twin for a customer in the automotive components domain, designed to help proactively monitor its logistics function. The Digital Twin has been designed to track production activities through a network of RFID antennas that log information on each new box filled with components, such as the type, quantity and position of the box itself. A partially automated logistic transport system is managed by a Fleet Manager based on a push/pull logic, which guarantees the supply of the components to the assembly machines, to the logistic supermarkets and to the staging and shipment areas. The Digital Twin oversees this process by predicting and reporting in advance any bottlenecks, accumulation or lack of boxes in certain areas. The Digital Twin, interfaced with the MES (Manufacturing Execution System), which is the system that orchestrates the activities of one or more production lines, accurately ensures the fulfilment of orders, as well as the optimisation of logistics spaces.


Concept Reply is the hardware and software development partner of the Reply Group specialized in IoT innovation. It offers solutions in the areas of Smart Infrastructure, Industrial IoT and Connected Vehicle. From the initial idea through the concept phase to implementation, operation and support. The company's numerous IoT specialists cover everything from hardware design and development to software implementation in embedded environments to edge computing software or cloud applications.