AI-Powered Digital Twin Services: See the Future of Your Operations.
Create a living, learning virtual model of your physical assets, processes, and supply chains.
Predict outcomes, prevent downtime, and perfect performance with zero real-world risk.
Trusted by Industry Leaders & Recognized for Excellence
Bridge the Gap Between Physical and Digital Worlds
In today's hyper-competitive landscape, operational blind spots are not just inefficient, they're existential threats. Unforeseen equipment failures, supply chain disruptions, and process bottlenecks cost millions in lost revenue and damage reputations. You're forced to make high-stakes decisions with incomplete data, reacting to problems instead of preventing them. The inability to safely test new ideas or train personnel for complex scenarios stifles innovation and introduces unacceptable risks. It's time to stop guessing and start knowing.
Why Partner with CIS for Your Digital Twin Initiative?
We don't just build models; we build virtual replicas of your business that drive tangible outcomes. Our unique blend of AI expertise, engineering rigor, and unwavering commitment to security makes us the ideal partner to navigate your digital transformation.
AI-Powered Predictive Insights
We go beyond simple visualization. Our Digital Twins are infused with advanced AI and machine learning models to deliver true predictive power, forecasting failures, optimizing processes, and simulating future scenarios with unparalleled accuracy.
Enterprise-Grade Security & Compliance
Your operational data is your most sensitive asset. As a CMMI Level 5, SOC 2, and ISO 27001 certified partner, we implement a Zero Trust security framework, ensuring your data's integrity, confidentiality, and availability are protected at all times.
End-to-End Partnership Model
From initial strategy and data integration to model development, deployment, and continuous optimization, we provide a complete, managed service. We act as an extension of your team, providing the expertise you need to succeed without the overhead.
Proven ROI & Phased Implementation
We focus on delivering measurable business value, fast. Our methodology starts with identifying high-impact use cases for a pilot project, demonstrating clear ROI before scaling across your enterprise, ensuring buy-in and minimizing risk.
100% In-House Expert Teams
We never outsource our core expertise. Your project is handled by our dedicated, on-roll team of 1000+ data scientists, AI engineers, 3D modelers, and cloud architects, ensuring seamless communication, accountability, and consistent quality.
Deep Domain & Systems Expertise
We understand both the physical and digital sides of your operation. Our experts are proficient in integrating with your existing OT/IT systems, including SCADA, MES, ERPs, and PLM platforms, creating a truly unified data ecosystem.
Scalable Cloud-Native Architecture
We build your Digital Twin on robust, scalable cloud platforms like AWS and Azure. This ensures your solution can grow with your business, handling massive data streams and complex simulations without compromising performance.
Focus on Actionable Outcomes
A Digital Twin is only valuable if it drives better decisions. We design our solutions with the end-user in mind, creating intuitive dashboards and workflows that translate complex data into clear, actionable insights for your operators and executives.
20+ Years of Engineering Excellence
Since 2003, we've delivered over 3000 successful projects for global enterprises. This legacy of engineering discipline means we deliver robust, reliable, and maintainable solutions that stand the test of time.
Our Comprehensive Digital Twin Services
We offer a full spectrum of services to design, build, and operate a Digital Twin that is perfectly aligned with your business objectives, from strategic roadmapping to real-time operational intelligence.
Digital Twin Consulting & Strategy
We help you navigate the complexities of Digital Twin adoption. Our strategic consulting ensures your initiative is built on a solid foundation, aligned with clear business goals, and poised for maximum impact. We define the roadmap from pilot to enterprise-wide deployment.
- Identify and prioritize high-ROI use cases specific to your industry and challenges.
- Develop a comprehensive technology and data architecture blueprint.
- Create a phased implementation roadmap that minimizes risk and accelerates time-to-value.
Data Integration & Platform Engineering
A Digital Twin is only as good as its data. We specialize in breaking down data silos, building robust data pipelines to connect your disparate IT and OT systems (like ERP, MES, SCADA, and IoT sensors) into a unified, real-time data foundation for your Digital Twin.
- Establish seamless connectivity with diverse operational and enterprise data sources.
- Build scalable, cloud-native data platforms on AWS or Azure to process and store vast data volumes.
- Ensure data quality, governance, and security to create a trusted "single source of truth."
3D Modeling & Physics-Based Simulation
We create high-fidelity, engineering-grade virtual models of your assets and environments. By integrating physics-based simulation, we enable you to test performance under a wide range of conditions, analyzing stress, thermal dynamics, and fluid flow without physical prototypes.
- Develop precise 3D models from CAD, BIM, or point cloud scan data.
- Integrate with leading simulation engines like Ansys or MATLAB/Simulink.
- Enable what-if analysis to optimize product design and operational parameters.
Process & Factory Simulation
Visualize and optimize your entire production line or facility. Our process simulation twins allow you to identify bottlenecks, test new layouts, optimize resource allocation, and improve throughput by running countless virtual scenarios before making a single physical change.
- Model material flow, machine utilization, and human-robot collaboration.
- De-risk factory re-tooling or expansion by validating plans in a virtual environment.
- Improve production scheduling and reduce work-in-progress inventory.
Asset Performance Digital Twins
Move from reactive repairs to a predictive maintenance strategy. Our Asset Performance Twins monitor the health of your critical equipment in real-time, using AI to predict failures before they happen, optimize maintenance schedules, and extend asset lifespan.
- Reduce unplanned downtime by up to 70% through early anomaly detection.
- Lower maintenance costs by shifting from time-based to condition-based servicing.
- Increase overall equipment effectiveness (OEE) and operational reliability.
Supply Chain & Logistics Twin
Build a resilient and agile supply chain. We create a dynamic, end-to-end virtual model of your entire supply network, enabling you to simulate the impact of disruptions, optimize inventory levels, and improve logistics to enhance visibility and control.
- Test your supply chain's response to potential disruptions (e.g., port closures, supplier outages).
- Optimize inventory placement and transportation routes to reduce costs and delivery times.
- Improve demand forecasting and S&OP (Sales and Operations Planning) accuracy.
IoT & AI/ML Model Integration
We connect the physical and digital worlds. Our expertise in IoT ensures a constant stream of real-time data from your assets, while our AI/ML integration turns that data into predictive insights, making your Digital Twin a living, learning, and evolving system.
- Deploy and manage IoT sensors and gateways for comprehensive data capture.
- Develop and integrate custom machine learning models for prediction, classification, and optimization.
- Implement MLOps practices to ensure your AI models remain accurate and effective over time.
Real-World Impact: Our Digital Twin Success Stories
Explore how we've helped enterprises like yours leverage Digital Twin technology to achieve breakthrough results in efficiency, reliability, and resilience.
Predictive Maintenance for a Global Automotive Manufacturer
The Problem
The client was plagued by frequent, unpredictable failures on their CNC machining lines. Each hour of downtime cost over $50,000 in lost production. Their preventative maintenance schedule was inefficient, leading to unnecessary servicing of healthy machines while failing to catch imminent breakdowns.
Key Challenges
- Integrating real-time data from legacy CNC controllers and new IoT sensors.
- Developing accurate AI models to predict failures based on vibration, temperature, and power consumption data.
- Creating an intuitive dashboard for plant managers to act on predictive alerts.
- Ensuring the solution was scalable across 15 global manufacturing plants.
Our Solution
We developed an Asset Performance Digital Twin for their most critical CNC machines. The solution provided a real-time, data-driven view of machine health and predicted failures with over 95% accuracy.
- Deployed a custom IoT gateway to collect and stream high-frequency data from diverse machine assets.
- Built and trained a suite of machine learning models (using LSTM and Random Forest algorithms) on AWS SageMaker.
- Created a unified dashboard visualizing real-time asset health, remaining useful life (RUL) estimates, and actionable maintenance alerts.
- Established a "Digital Thread" linking performance data back to the machine's design and operational history for root cause analysis.
Building Resilience for a Third-Party Logistics (3PL) Provider
The Problem
The client's global supply chain was a black box. They lacked end-to-end visibility and struggled to react to disruptions like weather events, port congestion, and supplier delays. This led to missed delivery windows, costly expedited shipping, and dissatisfied customers.
Key Challenges
- Aggregating real-time data from carriers, TMS, WMS, and public data feeds (weather, traffic).
- Modeling complex, multi-modal logistics networks with thousands of nodes.
- Developing a simulation engine to accurately model the ripple effects of disruptions.
- Providing a user-friendly interface for supply chain planners to run what-if scenarios.
Our Solution
We constructed a comprehensive Supply Chain Digital Twin, providing a live, end-to-end view of their entire logistics network and a powerful simulation environment to test for resilience.
- Integrated over 50 disparate data sources using a cloud-based data lake on Azure.
- Developed a graph-based model of the supply chain network to map all dependencies.
- Built a custom simulation engine that allowed planners to inject disruptions and visualize their impact on inventory, costs, and delivery times.
- Created a "control tower" dashboard that provided real-time visibility and proactive alerts for potential issues.
Optimizing a Fleet of Wind Turbines for an Energy Provider
The Problem
The client needed to maximize the energy output and lifespan of their aging wind turbine fleet. Sub-optimal blade pitch and yaw control were leaving potential energy uncaptured, and a conservative maintenance strategy was increasing operational costs without effectively preventing gearbox failures.
Key Challenges
- Creating high-fidelity aerodynamic and mechanical models of the turbines.
- Streaming and processing massive volumes of SCADA data and weather forecasts.
- Developing an AI-powered recommendation engine for real-time control adjustments.
- Accurately predicting component fatigue and remaining useful life.
Our Solution
We created a Digital Twin for each wind turbine in the fleet, combining physics-based models with AI to optimize performance and predict health in real-time.
- Developed a hybrid model combining computational fluid dynamics (CFD) with machine learning to predict power output under any wind condition.
- Integrated real-time SCADA data and hyperlocal weather APIs to feed the twin.
- Built a reinforcement learning agent that continuously recommended optimal pitch and yaw adjustments to maximize output while minimizing structural stress.
- Deployed predictive models to monitor gearbox and bearing health, shifting maintenance from a fixed schedule to a condition-based approach.
Our Proven 4-Step Digital Twin Implementation Process
We follow a structured, agile methodology to ensure your Digital Twin project moves from concept to value-generating reality efficiently and effectively.
1. Discover & Strategize
We begin with a deep dive into your operations, identifying key pain points and prioritizing use cases with the highest potential ROI. We co-create a strategic roadmap and a detailed architectural blueprint.
2. Integrate & Model
This phase focuses on building the foundation. We establish data pipelines from your IT/OT systems, clean and structure the data, and develop the high-fidelity 3D and physics-based models of your assets or processes.
3. Develop & Simulate
Here, we bring the twin to life. We develop and integrate the AI/ML models, build the simulation engine, and create the user-facing dashboards. Rigorous testing ensures the twin accurately reflects its physical counterpart.
4. Deploy & Optimize
We deploy the Digital Twin into your operational environment, train your team, and monitor its performance. Our engagement doesn't end at launch; we continuously refine the models and identify new opportunities for optimization.
Technology Stack & Tools We Master
We leverage a best-in-class technology stack to build robust, scalable, and intelligent Digital Twin solutions.
What Our Clients Say
Our 95% client retention rate is built on trust, transparency, and a relentless focus on delivering results.
"The level of detail in the simulation was astounding. We identified a critical bottleneck in our new production line layout before a single piece of equipment was moved. CIS saved us months of delays and millions in rework."
"CIS's team are true partners. They took the time to understand the nuances of our logistics network. The Digital Twin they delivered is now the central nervous system of our entire operation."
"We needed more than just a vendor; we needed deep technical expertise in both energy systems and AI. CIS delivered on all fronts. Their predictive models for our gas turbines are the most accurate we've ever seen."
"The security and compliance aspect was non-negotiable for us. CIS's certifications and transparent process gave our board the confidence to move forward. They handle our sensitive operational data with the utmost professionalism."
"The ability to train our new operators on a virtual replica of the plant has been revolutionary. Training time is down 40%, and we've had zero safety incidents with new hires since implementation. The Digital Twin is our ultimate training and safety tool."
"We engaged CIS for a pilot project. The value was so clear and the ROI so immediate that we signed a multi-year agreement to roll out the Digital Twin across our entire portfolio of commercial properties for energy optimization."
Frequently Asked Questions
Have questions? We have answers. Here are some of the most common inquiries about our Digital Twin services.
A typical pilot project, focused on a specific high-impact use case, takes between 12 to 16 weeks. This includes the initial discovery and strategy phase, data integration, model development, and deployment of a functional prototype to demonstrate value.
Security is our top priority. As a CMMI Level 5, SOC 2, and ISO 27001 certified company, we adhere to the strictest data security protocols. All client data is encrypted, stored in secure, isolated cloud environments, and governed by rigorous access controls. All intellectual property developed for you is fully transferred to you upon project completion.
The required data depends on the use case. It typically includes a combination of historical and real-time data from sources like IoT sensors (vibration, temperature), SCADA systems, Manufacturing Execution Systems (MES), Enterprise Resource Planning (ERP) systems, and engineering data like CAD or BIM files.
Absolutely. Our solutions are designed for seamless integration. We have extensive experience connecting with a wide range of enterprise systems, including SAP, Oracle, Microsoft Dynamics, as well as specialized operational technologies. We use modern API-first architecture to ensure smooth data flow.
ROI is calculated based on the specific use case. Key metrics often include cost savings from reduced unplanned downtime, increased revenue from improved production throughput, savings from optimized maintenance schedules, reduced waste, and cost avoidance from de-risking capital projects through simulation.
We offer flexible engagement models. While some clients prefer to have us manage the solution end-to-end, we also provide comprehensive training and knowledge transfer to empower your internal teams. We can tailor a support and maintenance plan that fits your specific needs and capabilities.
Ready to See Your Operations in a New Light?
Let's discuss how an AI-powered Digital Twin can unlock new levels of efficiency, resilience, and innovation for your business. Schedule a complimentary, no-obligation consultation with our experts today.