Digital Twins for Industry
Visualize, simulate, and optimize your plant before producing.
What is a Digital Twin?
A Digital Twin is a digital representation and simulation that allows predicting the different flows of processes, building a virtual factory or a parallel production process to make decisions and correct errors before they happen. It helps to avoid errors and reduce the time-to-market.
What Type of Digital Twin Do You Need?
Discover the most common applications that we implement in the plant:
Digital Twin of Production Lines and Assets
Model and analyze the behavior of machines, cells, and complete lines.
2d/3d Logistics Simulation
Optimize routes, AGVs, buffers, and internal resources with comparable scenarios.
Design Validation with CAD + VR
Virtually prototype products or machines and validate designs before manufacturing.
Virtual Training Environments
Safe and measurable training for operators in controlled conditions.
Main Functionalities
Digital Twin of Production Lines
- Digital modeling of lines and assets (plant or factory network).
- Reduction of downtime and inactivity.
- Real-time data for continuous analysis.
- Predictive and corrective maintenance.
- Measurable impact on KPIs such as OEE.
Simulation of Logistics Flows
- Virtual test fields (2D/3D) for routes, AGVs, robots, and operators.
- Optimization of routes and internal resources.
- Evaluation of logistics performance in real time.
- Comparison of past/future scenarios with historical and live data.
Design and Validation of Products or Machines
- Virtual prototypes with behavior in different environments.
- Fewer physical prototypes and greater start-up agility.
- Integration with CAD, 3D simulation, and virtual reality.
Benefits
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Fewer errors and stops
Start-up acceleration. -
Lower prototyping cost
Early validation and data-driven decisions. -
Better operational decisions
Greater visibility and data integration. -
OEE improvement
Efficient use of assets and resources. -
Cross-functional collaboration
Aligned engineering, operations, and quality.
Optimize your plant with secure and interoperable Digital Twins
Talk to an expertRelated Solutions and Services
MES – Manufacturing Execution System
Geprom’s MES is designed to act as the central hub of industrial operations, integrating with automation (SCADA, PLC), business (ERP), and support (quality, maintenance, logistics) systems. Its modular architecture allows for flexible scaling, from data capture to complete traceability.
- Native integration with SCADA/DCS for real-time data capture
- Connection with ERP for orders, stocks, and reporting
- Interoperability with quality, traceability, CMMS, and WMS modules
- Validation in SAP, Microsoft, SAGE, etc. environments
- Multi-site and multi-plant architecture
Energy Efficiency Software
Integration with CMMS, MES, SCADA, and electrical devices
Connected, supervised, and optimized energy in real time
Geprom’s energy efficiency software integrates with the rest of the plant architecture to provide a complete view of consumption. It connects with SCADA to acquire electrical data, with CMMS to optimize maintenance, and with MES to correlate consumption with productivity.
- Captures data from SCADA and electrical sensors
- Crosses energy consumption with OEE, batches, or shifts via MES
- Integration with CMMS for predictive energy maintenance
- Compatible with ISO audits and industrial energy regulations
APS – Advanced Planning and Scheduling
Integration with other systems (ERP, MES, SCADA, QMS, WMS)
Global vision and optimized production scheduling
Geprom’s APS system allows you to plan and sequence manufacturing orders considering the actual plant capacity and the restrictions of materials, machines, and personnel. Its integration with ERP, MES, and other industrial systems ensures dynamic, accurate planning aligned with the operation.
- Bidirectional connection with ERP (SAP, Dynamics, Oracle, SAGE, etc.)
- Real-time synchronization with MES for production execution
- Simulation of productive digital twin type scenarios
- Flexible programming in multiline and multiplant environments
- Resource optimization and bottleneck reduction
SCADA – Supervisory Control and Data Acquisition
Integration with PLC, MES, DCS and ERP
Total supervision and base for industrial digitization
Geprom’s SCADA system connects with plant devices (PLCs, sensors, actuators) and feeds data to systems such as MES or ERP. It is the basis of real-time supervision and a key pillar for the deployment of MOM architectures.
- Direct communication with PLCs and DCS
- Synchronization with MES for recipe control, alarms, and OEE
- Export of historical data to ERP or BI
- Flexibility to connect to existing sensors, HMI interfaces, and control systems
WMS – Warehouse Management System
Integration with ERP, MES, and IoT devices
Logistics and production synchronized in real time
Geprom’s WMS system integrates with the ERP to manage orders, stocks, and work orders, and with the MES to coordinate inputs, consumption, and returns. In addition, it connects with sensors, RFID tags, and logistics automation technologies (robots, AGVs, automatic shelving).
- Connection with MES for operational traceability and production orders
- Integration with ERP for logistics and finance
- Interoperability with RFID, barcodes, NFC, AGVs
- Advanced management of picking, returns, cross-docking
- Total logistics visibility from plant to dispatch
CMMS – Computerized Maintenance Management System
Integration with MES, ERP, WMS and IoT devices
Connected maintenance for a more efficient factory
Geprom’s GeTag CMMS software integrates in real time with MES, WMS and ERP to consolidate all information related to assets, maintenance, parts and resources. Its open architecture allows the incorporation of predictive maintenance technologies and advanced analytics.
- Connection with ERP for purchases, stocks, costs and planning
- Integration with MES for planning productive maintenance
- Synchronization with WMS for parts, technical warehouse and spare parts
- Connectivity with sensors, IoT, NFC/RFID tags
- Prepared for predictive maintenance and advanced analytics
QMS – Advanced Quality Management Software
Integration with MES, ERP, and inspection systems
Connected quality control and total traceability
QMS connects with MES and ERP to ensure a continuous flow of data between production, quality, and business. In addition, it integrates with LIMS systems, measuring devices, and artificial vision, capturing key parameters in real time to ensure product and process conformity.
- Direct interface with MES to activate automatic controls
- Synchronization with ERP for document and batch management
- Integration with sensors, scales, artificial vision, SCADA
- Compatible with ISO, FDA 21 CFR Part 11 standards
- Connectivity with laboratory systems (LIMS)
Industrial Control Tower
Integration with all MOM, ERP, IoT systems, and BI platforms
Centralized command center for global decision-making
Geprom’s industrial control tower collects data from MES, SCADA, ERP, and IoT sensors to provide a unified view of the entire factory or group of plants. It is the top layer of operational intelligence, ideal for multi-plant environments and distributed processes.
- Integration with MES, SCADA, ERP, IoT, sensors, and external devices
- Creation of personalized dashboards, accessible from any device
- Real-time decision-making based on cross-referenced data
- Global orchestration of processes, plants, and systems
- Automation of decisions based on operational rules
Success Stories
Our Clients
What our Clients Say
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“This project is a commitment to innovation that will allow us to evolve our business and thus guarantee the authenticity and quality of our tobacco. With Telefónica Tech’s traceability solution, we comply with European regulations on tobacco products and achieve comprehensive control and monitoring.”
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“The digital transformation project that we are starting aims to improve each and every one of the company’s processes, adapting to the new technological environments to achieve the highest level of effectiveness and efficiency at the Fini Company”
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“Measuring, controlling, and reducing the costs of bottling and storage processes is our challenge in a highly competitive environment with companies in the sector and declining consumption in all markets. Decisions regarding both processes, along with those related to quality, must be precise to offer the best service, and thus differentiate ourselves from our competitors.”
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“The IoT4DigitalTwin project, developed in consortium with Geprom and Gefasoft, has allowed us to incorporate the most advanced technologies of Industry 4.0, is bearing fruit, and represents an advance in boosting our competitiveness and efficiency.”
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“With the collaboration of Geprom and its GeTag platform, we have boosted the efficiency of our processes by centralizing business information and improving the customer service we offer.”
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“Through the technology consulting sessions, they outlined the implementation of Industry 4.0, indicating not only the areas for improvement that we were seeking, but also other improvements that will help us enhance our production and our work system.”
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“Proactively deploying a pilot test of the MES Objective system allowed us to verify the reduction of unnecessary costs to a minimum and allowed us to assess the investment in detail.”
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“Objective’s technical support service demonstrates its excellent knowledge time and again, available 24 hours a day”
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“In MES, master data can be fantastically integrated with production lines to eliminate paper on the factory floor. Furthermore, always having the correct data available is a necessity in our sector.”
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“The collaboration with Objective is very pleasant. The combination of Objective’s technical solution and Modiform’s experience has led to new ideas and developments that we now see again in the new version of Objective.”
The Digital Maturity Pyramid
What Level of Digital Maturity Does this Product Cover?
The Geprom Digital Twins are located in Level 5 of Digital Maturity, the most advanced stage of the pyramid.
At this level, organizations apply Artificial Intelligence, advanced simulation, and virtual environments to optimize their production, logistics, and product design processes in real time.
This level implies:
- The creation of virtual replicas of lines, machines, or complete processes.
- The simulation of logistics flows and validation of designs without stopping real production.
- The predictive analysis of scenarios with historical and live data.
- The continuous optimization of resources, spaces, and routes before executing them in the plant.
Still Have Questions?
Still have questions? Contact us and our team will be happy to help.
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