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Staff Reporter | Dhaka | Tuesday, September 23, 2025
T
he manufacturing and logistics sectors are on the brink of a major transformation. At the heart of this change is the next-generation technology known as the Digital Twin. By creating a virtual replica of a physical system or process, this technology enables real-time monitoring, analysis, and control.
How It Works
A digital twin is essentially a “digital mirror” of a factory, production line, or supply chain. Using IoT sensors, data analytics, and artificial intelligence, it can simulate real-world conditions and predict future outcomes. For instance, it can detect equipment malfunctions before they occur, helping to reduce waste and unplanned downtime.
Impact and Benefits
Globally, industries such as automotive, pharmaceuticals, and electronics are already reaping the benefits of digital twins.
- Predictive Maintenance: Potential to reduce unplanned downtime by 20–50%.
- Productivity Gains: Siemens reported a 31% increase in Overall Equipment Effectiveness (OEE) after implementing digital twin technology.
- Smarter Logistics: Companies like DHL are using digital twins to optimize warehouse operations and streamline supply chain management.
Opportunities for Bangladesh
For Bangladesh, especially in the ready-made garment (RMG) sector and logistics industry, digital twins could be a game-changer. Experts say adopting this technology would improve efficiency, boost competitiveness, and strengthen export performance in the global market.
Challenges Ahead
Despite the promise, challenges remain. High implementation costs, a shortage of skilled professionals, and cybersecurity risks are key barriers. Without proper planning and supportive policies, businesses may struggle to harness the full potential of digital twins.
Industry analysts believe the adoption of digital twin technology will expand rapidly within the next five years across manufacturing and logistics. By cutting costs, enhancing productivity, and improving service quality, it is poised to become more than just a technology — it will be the driving force of the Industry 4.0 revolution.
