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Performance is paramount for laboratories seeking a business advantage in a rapidly evolving sector. However, streamlining lab processes to improve efficiency can be costly, especially when it involves updating scientific workflows or moving large equipment and retraining operators. This cost can be difficult to justify when there are no guarantees the changes will result in a return on investment (ROI).
Labs need an economical method for experimenting with different setups so they don’t outlay unnecessary time, effort, and expense. If they could model scenarios first, they could choose the most effective improvements and present a robust business case to stakeholders before making physical changes in the lab.
Fortunately, there’s a technological solution. Digital Twins are computer models that can simulate changes and predict lab performance in various scenarios using the data labs already collect during their day-to-day operations. Insights from digital twins can help labs determine which changes will enable them to meet their strategic goals and provide the best ROI.
A digital twin is a virtual replica of a physical entity. In the laboratory context, digital twins are computer models that mirror the lab’s environment, equipment, processes, and workflows. Integrated with real-time data, they can provide an accurate, dynamic representation of the lab’s operations, generating sophisticated simulations and predictive analytics to inform decision-making.
Many laboratory informatics programs don’t leverage digital twins and their predictive capabilities. Instead, labs focus on gathering transactional data—the detailed records of interactions and processes occurring in the lab. For example, they record data related to sample testing, the usage of equipment and consumables, and operator actions. They then analyze this transactional data with a historical lens to describe past performance.
This data is crucial for maintaining accurate records, ensuring compliance with regulations, and supporting research and diagnostic activities. At the same time, it’s a valuable, often untapped, resource for predicting future lab performance when integrated with a digital twin to perform system modeling and what-if analyses.
Digital twins are already used to improve performance in manufacturing, oil and gas, supply chain, and many other industries. Rolls-Royce, for example, uses digital twins to capture engine data to provide enhanced support and maintenance services for customers. FMC Technologies worked with Siemens to use digital twins to optimize its product design and processes in the energy sector. Digital twins are also revolutionizing diagnostics in healthcare, optimizing treatments, supporting remote monitoring, and enabling early disease detection.
In a lab environment, there are endless ways digital twins can help streamline processes and workflows to improve performance. Here are some of the most common:
One of the primary advantages of digital twins is their ability to predict equipment failures before they occur. By continuously monitoring the performance and condition of lab instruments, digital twins can identify patterns and anomalies that signal potential issues. Labs that use predictive maintenance can minimize downtime, ensuring operations run smoothly and efficiently.
Digital twins enable labs to simulate different scenarios and optimize resource allocation. For instance, labs can test various staffing models, equipment configurations, and workflow designs to identify the most efficient setup. This capability helps labs make data-driven decisions that enhance productivity and reduce operational costs.
With digital twins, labs can conduct virtual experiments and test new methodologies without disrupting live operations. This ability to experiment in a risk-free environment fosters innovation and accelerates the development of new processes and techniques. Labs can iterate quickly, refine their approaches, and stay at the forefront of scientific advancements.
Quality control is crucial in lab settings. Digital twins allow for real-time monitoring and analysis of lab processes, ensuring adherence to standards and protocols. Any deviations can be immediately detected and addressed, resulting in higher accuracy, consistency, and reliability in lab outputs.
The wealth of data generated by digital twins provides valuable insights into lab performance. By analyzing this data, labs can identify trends, pinpoint inefficiencies, and uncover opportunities for improvement. These insights enable labs to optimize operations and achieve better outcomes.
A consultant with the appropriate domain, technology, software engineering, and regulatory expertise can help your lab develop a digital twin without using resources already tasked with maintaining daily operations.
At Semaphore Solutions, we assess a lab’s needs and consider the key areas where digital twins could add value. This guides the development and deployment of a digital twin strategy. We then help select the technology platform that best meets the lab’s requirements—whether an off-the-shelf product with customizations or building an entirely new solution. It’s important that the platform can be integrated with existing lab software, and that it provides real-time analytics and a user-friendly interface.
Because digital twins rely on accurate, real-time data from various sources, we also ensure that the necessary data collection systems and sensors are in place. Data must be collected from lab equipment, workflows, and personnel to create a comprehensive digital representation of the lab.
Next, we develop the digital twin models to mirror the lab’s operations and validate that the predictions match actual performance. Models generally require fine-tuning and refining in an iterative process, and monitoring over time for continuous improvement. They must also be updated as lab operations evolve so they remain an accurate representation of the lab environment.
Our team can help train lab personnel to use digital twins effectively. We provide ongoing support and maintenance of the digital twin solution to ensure it continues to provide valuable business insights.
Digital twins represent a powerful tool for labs seeking to enhance performance and stay competitive as the sector and regulations evolve. By leveraging digital twins, labs can predict equipment failures, optimize resource allocation, drive innovation, improve quality control, and gain valuable strategic insights.
If you’d like to predict lab performance before changing your workflows or making efficiency improvements, get in touch for a free consultation.
