AI-Powered Digital Twins: See the Future of Your Operations, Today.
We build dynamic, real-time virtual replicas of your most critical assets, processes, and
supply chains.
Move from reactive problem-solving to predictive, data-driven optimization.
Trusted by Industry Leaders for Mission-Critical Operations
Stop Reacting to Problems. Start Predicting Outcomes.
In today's hyper-competitive landscape, operational blind spots, unexpected downtime, and supply chain disruptions aren't just inconveniences—they're direct threats to your bottom line. Relying on historical data and reactive maintenance is like driving while looking in the rearview mirror. A Digital Twin for Enterprise Operations gives you a forward-looking, dynamic view, allowing you to simulate, predict, and optimize in a risk-free virtual environment before committing resources in the real world. It’s the critical shift from "what happened?" to "what will happen, and how can we make it better?"
Why Partner with CIS for Your Digital Twin Initiative?
We combine deep engineering expertise with strategic business acumen to build Digital Twins that deliver measurable value, not just technical novelty.
Outcome-Focused ROI
We don't build tech for tech's sake. We start by identifying your most critical business challenge—be it downtime, throughput, or cost—and build a targeted Digital Twin to solve it, ensuring a clear and rapid return on your investment.
Expert Data Integration
Our core strength lies in unifying your disparate data sources. We seamlessly connect your OT systems (SCADA, MES, PLCs) with your IT landscape (ERP, SCM) to create the single source of truth essential for an accurate Digital Twin.
Live, Dynamic Models
Our Digital Twins are not static simulations. They are living, breathing models fed by real-time IoT data, continuously learning and evolving to provide the most accurate predictions and operational insights.
End-to-End Managed Service
From initial strategy and data engineering to AI model development and ongoing support, we provide a complete, managed service. We act as an extension of your team, providing the specialized skills you need to succeed.
Platform-Agnostic Approach
We are not tied to a single vendor. We leverage the best-in-class platforms and technologies (from AWS and Azure to NVIDIA Omniverse) to build a solution that is right for your specific environment and goals.
CMMI Level 5 Process Maturity
Benefit from enterprise-grade quality and process optimization. Our CMMI Level 5 appraisal ensures your project is delivered with the highest standards of predictability, efficiency, and quality, minimizing risk.
AI-Augmented Talent
Our teams are AI-enabled, leveraging advanced tools to accelerate development, improve code quality, and uncover deeper insights from your data, delivering superior results faster than traditional teams.
Secure & Compliant by Design
With certifications like ISO 27001 and SOC 2, we build security and compliance into the foundation of your Digital Twin, protecting your sensitive operational data and intellectual property.
20+ Years of Enterprise Experience
Since 2003, we've been helping enterprises solve complex technical challenges. We bring decades of experience in software engineering and systems integration to your Digital Twin project.
Our Comprehensive Digital Twin Services
We offer a full spectrum of services to design, build, and scale Digital Twins that transform your physical operations into intelligent, data-driven ecosystems.
Asset Digital Twins for Predictive Maintenance
Create virtual replicas of your critical machinery and equipment to move from reactive repairs to proactive, predictive maintenance strategies.
- Reduce unplanned downtime by up to 50%.
- Extend asset lifespan and optimize maintenance schedules.
- Monitor real-time health and performance metrics.
Process Digital Twins for Manufacturing Optimization
Simulate your entire production line to identify bottlenecks, test new configurations, and optimize throughput without disrupting live operations.
- Increase Overall Equipment Effectiveness (OEE).
- Analyze and eliminate root causes of production delays.
- Train operators in a safe, virtual environment.
Supply Chain & Logistics Digital Twins
Model your end-to-end supply chain to improve visibility, simulate disruptions, and optimize inventory, routing, and network design.
- Test resilience against potential delays or shortages.
- Optimize inventory levels across your network.
- Improve on-time delivery and reduce transportation costs.
Warehouse & Facility Digital Twins
Optimize the layout, material flow, and resource allocation within your warehouses, distribution centers, or entire factories.
- Improve labor efficiency and resource utilization.
- Simulate the impact of automation (e.g., AGVs, robotics).
- Enhance safety by simulating pedestrian and vehicle traffic.
Product Lifecycle Digital Twins
Create a digital thread that connects a product from design and manufacturing through to in-field operation and end-of-life, enabling continuous improvement.
- Accelerate product development cycles.
- Incorporate real-world usage data into future designs.
- Offer data-driven, value-added services to customers.
Energy & Utilities Network Twins
Model electrical grids, pipelines, or renewable energy farms to optimize energy distribution, predict load, and manage asset health across vast networks.
- Improve grid stability and reduce outages.
- Optimize energy generation and distribution in real-time.
- Manage regulatory compliance and reporting.
Digital Twin Strategy & Consulting
We help you define a clear roadmap, identify high-value use cases, and build a robust business case for your Digital Twin initiative.
- Align technology investment with strategic business goals.
- Develop a phased implementation plan to de-risk the project.
- Calculate potential ROI and key performance indicators.
IoT & Data Integration Services
The foundation of any Digital Twin is data. We connect your sensors, PLCs, and enterprise systems to build a reliable, real-time data pipeline.
- Integrate legacy OT equipment with modern cloud platforms.
- Ensure data quality, security, and scalability.
- Implement edge computing for low-latency data processing.
3D Modeling & Visualization
We create high-fidelity, engineering-grade 3D models of your assets and environments, providing an intuitive and immersive interface for your Digital Twin.
- Convert CAD/BIM files and point cloud scans into usable models.
- Develop interactive dashboards and AR/VR experiences.
- Overlay real-time data onto 3D visualizations.
Physics-Based & AI/ML Simulation
We develop and integrate the core simulation models, combining physics-based principles with machine learning to create highly accurate predictive capabilities.
- Build models for thermal dynamics, structural stress, and fluid flow.
- Train ML models to predict failures and anomalies.
- Enable complex "what-if" scenario analysis.
AI-Driven "What-If" Scenario Analysis
Leverage your Digital Twin to run powerful simulations of future events, from demand spikes to equipment failures, and develop optimal response strategies.
- Test changes to production schedules or supply routes risk-free.
- Evaluate the impact of capital investments before purchase.
- Develop data-backed business continuity plans.
AR/VR Integration for Field Service
Empower your frontline workers by overlaying Digital Twin data onto the physical world through augmented and virtual reality applications.
- Provide remote expert assistance to on-site technicians.
- Visualize real-time sensor data directly on the equipment.
- Guide complex repair and maintenance procedures.
Autonomous Operations & Control Loop
Evolve your Digital Twin from a decision-support tool to a decision-making engine that can autonomously optimize and control physical processes.
- Enable self-optimizing production lines.
- Automate energy consumption based on real-time pricing and demand.
- Implement closed-loop quality control systems.
Digital Twins for ESG & Sustainability
Model and optimize your resource consumption, carbon footprint, and waste streams to achieve your environmental, social, and governance goals.
- Track and report on energy, water, and material usage.
- Simulate the impact of sustainability initiatives.
- Optimize for both operational efficiency and environmental impact.
Federated Digital Twins for Ecosystems
Connect your Digital Twin with those of your suppliers and customers to create a shared, secure view of the entire value chain, enabling unprecedented collaboration.
- Gain end-to-end visibility across multiple organizations.
- Collaboratively manage inventory and logistics.
- Build more resilient and transparent supply networks.
Our Proven 4-Step Digital Twin Implementation Process
We follow a structured, agile methodology to move from concept to a fully operational, value-generating Digital Twin, ensuring alignment and de-risking your investment at every stage.
1. Discover & Strategize
We begin with a deep dive into your operations, identifying the most impactful use cases and defining clear success metrics. This phase includes stakeholder workshops, data source audits, and creating a strategic roadmap and business case.
2. Build & Integrate (Pilot)
Starting with a high-value pilot, we connect data sources, build the foundational 3D and physics/AI models, and develop the core platform. This agile approach delivers tangible results quickly and validates the solution before scaling.
3. Scale & Enhance
Once the pilot proves its value, we expand the Digital Twin's scope. This involves connecting more assets, enriching the model with more data, and adding advanced features like AR/VR integration and autonomous control loops.
4. Optimize & Support
A Digital Twin is a living system. We provide continuous support, monitoring model accuracy, retraining AI algorithms, and working with your team to uncover new opportunities for optimization and operational improvement.
Technology & Platforms We Master
We are platform-agnostic and leverage a best-in-class technology stack to build robust, scalable, and secure Digital Twin solutions tailored to your enterprise environment.
Real-World Impact: Our Digital Twin Success Stories
Explore how we've helped enterprises like yours turn complex operational data into a powerful competitive advantage.
Reducing Unplanned Downtime for an Automotive Parts Manufacturer
Industry: AutomotiveClient Overview
A leading Tier 1 automotive supplier with multiple plants across the USA was facing significant losses due to unplanned downtime on their critical CNC machining lines. Their reactive maintenance approach was costly and inefficient, impacting production targets and delivery schedules.
Key Challenges
- Frequent, unpredictable failures of key components like spindles and servos.
- Lack of real-time visibility into machine health.
- Inability to correlate operational data (vibration, temperature) with failure events.
- High costs associated with emergency repairs and lost production.
Our Solution
CIS developed an Asset Digital Twin for their most critical CNC line. Our solution involved:
- Integrating real-time data from vibration, temperature, and power consumption sensors.
- Building an AI/ML model trained on historical failure data to predict component degradation.
- Creating a 3D visualization of the CNC line where maintenance managers could monitor asset health in real-time.
- Generating automated alerts for maintenance teams when the model predicted a high probability of failure within a specific timeframe.
Optimizing Warehouse Throughput for a Global 3PL Provider
Industry: LogisticsClient Overview
A major third-party logistics (3PL) provider was struggling to meet peak season demand at their primary distribution center. Their existing layout led to congestion, inefficient picking routes, and delays in order fulfillment, threatening key customer SLAs.
Key Challenges
- Bottlenecks in high-traffic areas during peak hours.
- Suboptimal inventory slotting strategies.
- Difficulty in evaluating the potential impact of new automation systems.
- High labor costs due to inefficient travel paths for pickers.
Our Solution
We built a Process Digital Twin of the entire warehouse, simulating the movement of goods, people, and equipment. The solution enabled them to:
- Model material flow from receiving to shipping, identifying key congestion points.
- Run "what-if" scenarios to test new layouts and inventory slotting strategies.
- Simulate the introduction of Autonomous Mobile Robots (AMRs) to quantify the potential ROI.
- Optimize picking paths and resource allocation based on real-time order volumes.
Improving Asset Performance Monitoring for a Major Utility
Industry: Energy & UtilitiesClient Overview
A regional energy utility needed to improve the monitoring and maintenance of its aging network of distribution transformers. Physical inspections were infrequent and costly, and they lacked a centralized system to predict failures, which could lead to significant outages.
Key Challenges
- Managing thousands of geographically dispersed assets.
- Relying on manual, time-based inspections rather than condition-based monitoring.
- Inability to predict transformer failures based on load, weather, and age.
- Risk of costly outages and regulatory penalties.
Our Solution
CIS created a Network Digital Twin that integrated data from multiple sources to provide a holistic view of asset health. The solution included:
- Aggregating data from smart meters, weather APIs, and historical maintenance records.
- Developing a machine learning model to calculate a real-time "health score" for each transformer.
- Creating a geospatial dashboard that visualized the entire network, highlighting at-risk assets.
- Automating the generation of work orders for proactive maintenance based on predictive alerts.
What Our Clients Say
We pride ourselves on building long-term partnerships that drive real results.
"The Digital Twin CIS built for our production line was a game-changer. We identified bottlenecks we never knew existed. Their team's ability to integrate our legacy systems was impressive."
Aaron Welch
Director of Operations, Automotive Manufacturer
"We were skeptical about the ROI of a Digital Twin, but CIS's pilot-based approach proved the value in just a few months. The predictive maintenance alerts have already saved us from two major outages."
Amelia Norton
VP of Engineering, Energy Corp
"Simulating our warehouse expansion with the Digital Twin saved us millions in potential design mistakes. The ability to test different layouts virtually is incredibly powerful. CIS delivered beyond our expectations."
Bryce Harlan
Head of Supply Chain Innovation, Global Logistics
Frequently Asked Questions
Your most common questions about Digital Twins, answered.
The ROI varies by use case but is often significant. For predictive maintenance, clients typically see a 10-15% reduction in maintenance costs and a 30-50% reduction in unplanned downtime. For process optimization, improvements in throughput or efficiency can be in the 15-25% range. We work with you to build a detailed business case and ROI model specific to your goals during the initial strategy phase.
The timeline depends on the complexity. A focused pilot project, targeting a single asset or process, can often deliver initial value within 3-6 months. A full-scale, factory-wide Digital Twin is a more extensive program implemented in phases over 12-24 months. Our agile, pilot-first approach is designed to deliver value quickly and build momentum.
Absolutely. This is a very common challenge and a core part of our expertise. Our first step is always data engineering and integration. We have extensive experience connecting to a wide range of OT and IT systems (MES, SCADA, ERPs, etc.) to cleanse, contextualize, and unify your data into a pipeline that can reliably feed the Digital Twin.
We offer flexible engagement models. While some clients have in-house data scientists and engineers who co-develop with us, many rely on us for a fully managed service. We can handle the ongoing monitoring, model retraining, and support, allowing your team to focus on using the insights to drive operational improvements. We also provide comprehensive training and documentation to empower your users.
A Digital Twin is a major evolution from both. Unlike standard simulation, a Digital Twin is connected to the physical asset in real-time and continuously learns and updates itself. Unlike a SCADA system, which primarily shows you *what is happening now*, a Digital Twin uses that data with AI/ML to predict *what will happen next* and allows you to simulate *what would happen if* you made a change.
Ready to Build a Predictive Digital Twin of Your Operations?
Let's talk about your most pressing operational challenges. Schedule a free, no-obligation consultation with our Digital Twin experts to explore potential use cases and map out a strategy for your business.