Digital Twin

Overcome Limits for Groundbreaking Performance

As plant operations become increasingly more intricate, the demand for new ways to meet KPIs and targets has never been greater. The fusion of technology and data-driven decision-making is here to pave the way forward. At the heart of this transformative journey lies the concept of the digital twin. Imagine having a virtual double of your entire operation—a digital twin not only duplicates every detail of your processes but also holds a cornucopia of historical insights and data sets.

Picture being able to see precise throughput and production rates. Plant managers can make pivotal but informed decisions and then view the projected efficiency changes as if they were already live. This isn't science fiction; it's a game-changing reality. A digital twin is more than just a model; it's a strategic tool that can empower your business to forecast future performance with remarkable accuracy and enable effective decision-making for safety, reliability, and profitability.



Begin the Digital Twin Benefits Journey Now:

  • Enhanced performance optimization: Digital twins optimize assets, processes, and systems by leveraging real-time data and simulation capabilities. This leads to reduced downtime, proactive decision-making, and the ability to ensure actual performance meets planned performance.
  • Improved maintenance strategies: Predictive maintenance based on real-time asset data minimizes failures, reduces downtime, and optimizes maintenance activities. Early anomaly detection enables timely intervention and efficient resource allocation.
  • Refined decision-making: Digital twins provide comprehensive insights into asset behavior and performance, enabling data-driven decision-making at all levels. They facilitate scenario evaluation, impact assessment, and the selection of favorable actions.



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The Benefits of Digital Twins

More Effective Decision-Making

Experts can review recommended strategies to assess the impact of each recommended approach.

Improved Safety & Reliability

Digital twins mimic asset performance, which can be used to predict failures and avoid risks; this improves worker safety and plant reliability.

Increased Profitability

The digital twin allows “What if?” and “What’s best?” scenarios to be run simultaneously to determine available strategies that maximize profitability. 

Digital twins also offer value in operational efficiency and insights into how products are used and how they can be improved:

  • Field and line employees have the information they need to understand the bottom-line impact of their day-to-day choices
  • Information flows across organizational boundaries
  • Second-guessing of decisions is minimized
  • Unit issues are identified and resolved faster
  • Lost profit opportunities are minimized
  • Performance gap visibility is improved
  • Modeling, visualization and reporting tools are seamlessly integrated

Yokogawa's Digital Twin Solutions


Enterprise Insight

A series of business and financial Key Performance Indicators (KPI’s) are updated in real-time, plan versus actual, as part of an enterprise-wide balanced scorecard for corporate situational awareness. Advanced logic is applied to real-time operations data to project current and future understanding of the business for executives.


Capability Assurance

Key operator actions are captured, controlled and manipulated in real-time through monitoring and control of work processes. Minimize the learning curve for new operators, support change management and enable vastly improved scenario validation through operator training simulation and an ISA106-compliant modular procedure automation solution.


Advanced Production

Multivariable predictive controls drive the plant continuously to its optimum constraints by reacting to disturbances in a closed loop.


Value Chain Optimization

Drive agile and efficient alignment of supply of premium products as closely as possible to market demand with sufficient resilience or operational flexibility to readily adjust production and exploit market opportunities through supply chain planning, scheduling and production accounting.


Automation and Control Integrity

Digital representation of the live plant and its automation algorithms through the “twin” function of an Integrated Control and Safety System (ICSS) allows engineers to conduct fundamental process control tests at an engineering workstation, as well as any proposed adjustments before they are applied on the live plant.


Instrumentation and Equipment Productivity

Minimize the need for breakdown and preventative maintenance, reduce OPEX through advanced online monitoring and prediction of field device health, and process interface conditions that reduce unnecessary trips.


Advanced Chemistry

Highly intelligent devices, such as pumps, flowmeters, transmitters, and chemical analyzers provide total insight into their ongoing performance as well as the ability to adapt to changing duty requirements throughout the measurement device lifecycle.


Plant Process Optimization

Online and offline high-fidelity models for non-linear performance monitoring, simulation, and optimization using first principle kinetics deliver optimized yield performance, flow assurance, energy efficiency improvement, enhanced reliability and operator capability assurance.


Application Note

The digital twin enables the transfer of “designed intelligence” from the engineering phases of a capital project into “applied intelligence” that operations can leverage.

Application Note

Chemical Processing Special Report:  Understand  the Process of Open Process Automation

Sponsored by YOKOGAWA.


Digital twins are dynamic digital representations that enable companies to understand, predict and radically reorient their business processes.


Achieving autonomous operations is primarily about empowering the plant to run, learn, adapt and thrive in tomorrow’s environment—whatever that environment might be. Download this whitepaper to learn the steps in the journey to autonomous operations.

Media Publication
Digital Safety Transformation
(Digital Safety Transformation)
Edition 1 1
The Emerging Business Risk Management Strategy for OT Cybersecurity
(The Emerging Business Risk Management Strategy for OT Cybersecurity)
Futurecasting the Path to Autonomy
(Futurecasting the Path to Autonomy)
Platform for Shaping the Future of Advanced Manufacturing and Value Chains
(Platform for Shaping the Future of Advanced Manufacturing and Value Chains)
Y NOW 2021 Opening Keynote on Yokogawa's Vision
(Opening Keynote Outlines Yokogawa's Vision for Autonomous Operations and Smart Manufacturing)
Realizing Next Normal Business Resilience with Agile Autonomous Operations
(Realizing Next Normal Business Resilience with Agile Autonomous Operations)
How Digital Transformation Enables Autonomous Polymer Operations
(How Digital Transformation Enables Autonomous Polymer Operations)
Digitally Transforming Overall Safety
(Digitally Transforming Overall Safety)

A new digital risk management methodology combines four digital technologies to form the foundation of a sustainable safety regimen.

Read all about it, inside.

Five Industrial Automation Trends for 2022
(Five Industrial Automation Trends for 2022)
Digitally Transforming to Autonomous Operations and Smart Manufacturing 4.0 (Panel-Discussion)
(Digitally Transforming to Autonomous Operations and Smart Manufacturing 4.0)



Product Overview

In this video, Yokogawa’s DX Safety Leader, Taylor Schuler, explains how digitalization can benefit the many facets of safety in terms of assets, processes, and an empowered, connected workforce operating on-site and remotely.

Watch Now.

Product Overview

Watch the film by KBC who are supporting their clients in their efforts to address climate change and sustainability.


Watch this on-demand webinar to learn how digital twin technologies are moving process industries towards autonomous operations.


This webinar talks through a case study of how a client is using a remote operations center for their onshore oil field and how people, technology and processes need to be integrated to make it a success.


Watch this webinar and learn how value chain optimization can improve profitability, enhance capital efficiency, and reinforce license to operate. 

With many stakeholders in the operations planning process, different tools being used and different datasets it’s likely there will discrepancies interpreting the production results, making it harder to decide on the best improvements. Join this webinar which looks at operationalizing a digital twin in the context of Unit Performance Monitoring.
This webinar, delivered by KBC’s Pablo Montagna and Motiva’s Raul Adarme, will profile how Motiva’s Port Arthur refinery complex uses online energy monitoring and optimization.

Yokogawa and Sphera have teamed up to enable PHA-Pro® to produce the configuration files required for the Exaquantum Process Safety Monitoring environment. The result is a Digital Risk Management solution that utilizes the entire process safety investment to date.


Learn how to more efficiently match supply to demand through the digital twin.


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