Most twins don't know your manufacturing floor. Ours originates from it.
CAD models depict engineering design. Master data is static. Excel is a thing of the past. Seconity generates the digital twin directly from physical operations – every position, every status, every process step, in real time. As a byproduct of daily operations, without an extra project.
25 pages, no marketing. Architecture, data model, real-world examples.
A twin that doesn't know reality isn't one. It is a model.
Almost every industrial company today has some form of digital twin. And almost none of them knows what is actually happening in production right now.
- CAD data describe how the shop floor was built. Not what is stored, placed, or moving inside it today.
- ERP master data are static, manually maintained, and to some extent incorrect in every plant.
- Excel exports are outdated the moment they are generated.
- MES data capture process steps – but not the positions and states between steps.
Not forced. Generated. From every event in your operations.
Level 1 (Physical AI) automatically captures every movement, position, and status. Level 2 (APS) processes these events into valid planning variables. Together, this creates a living, accurate model of your production that updates itself every second.
Objects
Every machine, every material, every tool, every load carrier – identified and typed.
Positions
Indoor accurate to 10 cm, outdoor via GPS. Recorded as a digital thread.
States
Available, occupied, in progress, locked, calibration required – actual status instead of target status.
Process steps
Which order completed which process step, when, and where. Automatically documented.
Planning parameters
Actual WIP, capacity utilization, bottleneck forecasts – enriched from the APS feed.
Event history
The complete digital thread of every object. The foundation for traceability and the digital product passport.
“The digital twin is not a project. It is what remains when your operations are running.”
Asset Administration Shell, Product Passport, Traceability: Regulations demand precisely the data you are generating anyway.
Asset Administration Shell
Open standard for the interoperable digital twin. Seconity delivers AAS-compliant submodels directly from live operations.
Digital Product Passport
The DPP is gradually becoming mandatory. The data trail is created as a byproduct of every automated capture. Eliminate manual steps today – be DPP-ready tomorrow.
Traceability
Standard-compliant events that customers, suppliers, and auditors understand. The twin doesn't end at the factory gate.
Today and in three years.
AI agents
Via MCP, agents access the twin directly – working with the present instead of exports.
Simulation & What-if
Simulate rescheduling based on real-time conditions before it gets expensive.
Predictive Maintenance
Usage profiles, travel paths, and condition histories from physical capture.
Autonomous fleets
AMRs need a real-time picture of their environment – including objects without a wireless module.
On-time delivery forecasting
Actual WIP reveals which deadline will slip – before it slips.
Audit & Traceability
Seamless digital thread. Mandatory for regulated industries, not an option.
Two types of twins. Only one knows your shop floor.
ROI today. And along the way, your digital twin.
Architektur, Datenmodell und der Weg vom ersten Use Case zum lebendigen Zwilling – mit Praxisbeispielen aus der diskreten Fertigung.