Jennifer Lachky-Busch, 30.05.2023, 2 min.

The digital shadow in industrial production: Insights, that really help companies

  1. What is a digital shadow?
  2. Which sectors does the digital shadow cover?

In the world of industrial production, where machines and systems drive the manufacturing process, the concept of the "digital shadow" takes on special significance.


What is a digital shadow?

In the age of Industry 4.0 and advanced automation, every action, every process, and every machine leaves a digital trail that forms a digital shadow. This shadow holds invaluable insights to optimize production performance, improve quality and open up new opportunities.

susietec® is deeply engaged in the fascinating world of the digital shadow, with a particular focus on manufacturing, because it is already clear today that this technology can revolutionize operations and improve overall performance.

The digital shadow in industrial production includes the following sectors in particular:

Data collection and integration.

In modern industrial production facilities, data is collected from various sources such as sensors, machines, control systems, and even external systems such as supply chain management tools. This large amount of data represents the digital shadow of the production process and includes information on machine performance, production rates, energy consumption, material usage and much more.

Real-time monitoring and analysis

By collecting and analyzing data from the digital shadow, manufacturers gain real-time insights into the operational aspects of production. Performance indicators such as throughput, cycle times, downtime and quality metrics can be monitored to enable proactive decision making and timely interventions to optimize production performance.

Predictive maintenance

The digital shadow enables predictive maintenance practices by monitoring machine operating parameters. By analyzing historical data patterns, anomalies and precursors to failures, manufacturers can proactively plan maintenance activities, minimize unplanned downtime and maximize machine availability.

Process optimization

By taking advantage of the digital shadow, manufacturers can identify bottlenecks, inefficiencies and process deviations in their production operations. With this knowledge, they can optimize production processes, adjust parameters and fine-tune operations to increase productivity, reduce waste and improve overall efficiency.

Quality control and traceability

The digital shadow enables tracking and traceability of production processes and supports comprehensive quality control. Manufacturers can identify potential problems, track the cause of defects, and take timely corrective action to ensure compliance with quality standards and minimize product recalls.


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Intelligent automation

Integrating the digital shadow with advanced technologies such as artificial intelligence (AI) and machine learning (ML) enables intelligent automation solutions. By training algorithms with historical production data, manufacturers can develop predictive models, optimize workflows, and enable autonomous decision making to achieve greater efficiency and agility in the production environment.


Supply chain optimization

Digital shading extends beyond the boundaries of individual manufacturing facilities and provides opportunities to optimize the supply chain. By sharing relevant data with suppliers, partners and customers, manufacturers can improve collaboration, optimize demand forecasting, reduce delivery times and optimize overall supply chain economics.


Would you like to learn more about the digital shadow in the industrial environment?


The use of the digital shadow in industrial production holds tremendous potential to revolutionize manufacturing processes. By capturing, analyzing and using data generated during the production process, manufacturers can gain valuable insights, improve decision making and drive continuous improvement.

susietec® works closely with diverse customers on complex pilot projects. The common goal is to optimize production efficiency, improve quality control, and unlock new opportunities for innovation and growth in the dynamic world of industrial manufacturing.


Contact us. We would be happy to develop systems to work with you to capture the digital shadow of your industrial company, analyze it and transform it into your company.

About the author

As Portfolio Manager IoT, Jennifer Lachky-Busch has been responsible for the strategic development and marketing of the kontron susietec® toolset since 2021. On the susietec® blog she deals with current trends, informs about product news and answers exciting questions around the topics IIoT and Industry 4.0.

Jennifer Lachky-Busch Portfolio Manager