See Your Entire Production Line in Real Time
Track every station from raw material feed through final packaging. Identify bottlenecks, predict throughput, and simulate line changes before you make them.
How It Works
From raw PLC signals to production intelligence in three steps.
Connect
Tap into existing PLCs, CNCs, and I/O modules via OPC UA, Modbus, or EtherNet/IP. No production line changes required.
Model
Station cycle times, buffer levels, OEE components, and quality metrics are calculated from raw signals — not manual data entry.
Simulate
Test line balancing changes, changeover sequences, and capacity additions on the digital twin before disrupting production.
What You Can Simulate
Every production scenario — tested safely on the digital twin before committing.
Line balancing
Simulate redistributing work content across stations to eliminate the bottleneck and increase throughput.
Changeover scheduling
Model different product sequencing to minimize total changeover time across a shift.
Quality root cause
Correlate a spike in defects with equipment parameters (tool wear, temperature drift) to find the root cause.
Capacity what-if
Add a parallel station in the model and see the throughput impact before approving the capital expenditure.
Predictive maintenance
Schedule station maintenance during planned changeovers to eliminate unplanned production stops.
Shift handover briefing
Auto-generate a shift summary with OEE, bottleneck events, quality alerts, and predicted next-shift output.
Traditional MES vs. Digital Twin
MES tells you what happened last shift. A digital twin tells you what will happen next.
| Feature | Traditional MES | TwinEdge Digital Twin |
|---|---|---|
| Production visibility | End-of-shift reports | Real-time per-station metrics |
| Bottleneck detection | Walk the line | Automatic constraint identification |
| OEE decomposition | Manual data entry | Auto-calculated from sensors |
| What-if analysis | Spreadsheet models | Live simulation with real data |
| Quality root cause | After-the-fact investigation | Real-time correlation engine |
| Changeover optimization | Tribal knowledge | Data-driven sequencing |
See Your Production Line as a Digital Twin
Share your line layout and station configuration. We will build a live demo showing your actual bottlenecks, OEE, and throughput predictions.