Digital Twin Feasibility Plan & Value Checklist

{ "Title": "Digital Twin Feasibility Plan & Value Checklist", "IntroductionHtml": "

Use this guided template to run a short, structured feasibility study for a focused digital twin. Capture the decision you expect the twin to enable, the specific signals and models required, integration and safety constraints, measurable success criteria, and a clear go/no-go recommendation. Aim for a time-boxed pilot with a responsible owner and measurable outcomes.

Complete the form below as a cross-functional team (operations, engineering, data, safety, and IT) so the study reflects real operational constraints and ownership.

", "SubmitLabel": "Save Feasibility Plan", "SuccessMessage": "Feasibility plan saved. Use this plan to coordinate your pilot, collect data, and return for final recommendation and sign-off.", "DataType": "DigitalTwinFeasibilityForm", "SchemaVersion": "1.0", "Fields": [ { "Key": "project_name", "Label": "Project name", "FieldType": "text", "HelpText": "A concise name that identifies the line, cell, or asset (e.g., 'Line 3 Press Stacker Twin').", "Required": true }, { "Key": "owner", "Label": "Responsible owner (name & role)", "FieldType": "text", "HelpText": "Who will be accountable for the pilot and the go/no-go decision (include role).", "Required": true }, { "Key": "decision_enabled", "Label": "Hypothesis: What operational decision will the twin enable?", "FieldType": "textarea", "HelpText": "Describe the specific decision or class of decisions the twin is expected to improve (e.g., faster root-cause isolation, shift-level scheduling adjustments, predictive maintenance actions).", "Required": true }, { "Key": "primary_metric", "Label": "Primary outcome metric", "FieldType": "text", "HelpText": "The single most important metric you will measure to determine value (e.g., mean time to repair, first-pass yield, throughput minutes/hour, % unplanned downtime).", "Required": true }, { "Key": "baseline_value", "Label": "Baseline value (current) for primary metric", "FieldType": "text", "HelpText": "Numerical baseline or short description of current state (include measurement period).", "Required": true }, { "Key": "target_value", "Label": "Target value (expected with twin)", "FieldType": "text", "HelpText": "Realistic target for the primary metric that would justify the pilot investment.", "Required": true }, { "Key": "expected_benefit_rationale", "Label": "Why will the twin produce this improvement? (brief rationale)", "FieldType": "textarea", "HelpText": "Explain the causal chain (e.g., better root-cause leads to faster repairs, which reduces downtime).", "Required": true }, { "Key": "required_signals", "Label": "Required signals / data elements", "FieldType": "checkbox", "HelpText": "Select the signals expected to be required. Add others in 'other_signals'.", "Options": [ { "Value": "timestamped_production_counts", "Label": "Timestamped production counts" }, { "Value": "equipment_status_tags", "Label": "Equipment status / state tags (running, idle, fault)" }, { "Value": "vibration_temperature", "Label": "Sensors: vibration / temperature / pressure" }, { "Value": "process_parameters", "Label": "Process parameters (speeds, feeds, pressures)" }, { "Value": "alarms_fault_codes", "Label": "Alarms and fault codes" }, { "Value": "quality_measurements", "Label": "Quality measurements / inspection results" }, { "Value": "maintenance_history", "Label": "Maintenance history / work orders" } ], "Required": true }, { "Key": "other_signals", "Label": "Other required signals (free text)", "FieldType": "textarea", "HelpText": "List any additional data elements not covered above." }, { "Key": "data_sources", "Label": "Where does each signal come from? (systems, tags, files)", "FieldType": "textarea", "HelpText": "Identify the concrete sources (PLC tags, historian, MES tables, CSV exports, vision system outputs). Note owners and access constraints.", "Required": true }, { "Key": "data_frequency", "Label": "Required data frequency", "FieldType": "select", "HelpText": "How often must data be available for the twin to be useful?", "Options": [ { "Value": "subsecond", "Label": "Sub-second / high-frequency" }, { "Value": "seconds", "Label": "Seconds" }, { "Value": "minutes", "Label": "Minutes" }, { "Value": "shift_level", "Label": "Shift-level (aggregates)" }, { "Value": "batch", "Label": "Batch / end-of-run" } ], "Required": true }, { "Key": "data_quality", "Label": "Data readiness & quality checklist", "FieldType": "checkbox", "HelpText": "Confirm the minimum data readiness items. Check those that are true today.", "Options": [ { "Value": "accessible", "Label": "Data is accessible via a documented endpoint or export" }, { "Value": "timestamped_synced", "Label": "Signals have reliable timestamps and can be synchronized" }, { "Value": "sufficient_history", "Label": "Sufficient historical data exists for initial model training" }, { "Value": "complete_coverage", "Label": "Coverage across shifts and operating modes is adequate" }, { "Value": "labelled_quality", "Label": "Quality events are labelled or traceable" }, { "Value": "consistent_definitions", "Label": "Signal definitions and units are documented and consistent" } ], "Required": true }, { "Key": "modeling_needs", "Label": "Modeling and analytics required", "FieldType": "textarea", "HelpText": "Describe the types of models (physics-based, statistical, anomaly detection, digital process twin, hybrid), required fidelity, and whether off-the-shelf algorithms may suffice.", "Required": true }, { "Key": "integration_points", "Label": "Required integration points", "FieldType": "textarea", "HelpText": "List systems to integrate for data in, decisions out, or visualization (e.g., MES, CMMS, SCADA, operator HMI, scheduler). Identify whether the integration must be read-only or must support action triggers.", "Required": true }, { "Key": "safety_and_constraints", "Label": "Safety, compliance or operational constraints", "FieldType": "textarea", "HelpText": "Note safety, regulatory, or process constraints that limit the twin’s actions or who can act on its outputs (e.g., no automated actuation without human-in-the-loop).", "Required": true }, { "Key": "pilot_scope", "Label": "Pilot scope (which line / asset / shift / time window)", "FieldType": "text", "HelpText": "Keep scope narrow and clearly bounded to reduce risk and cost.", "Required": true }, { "Key": "pilot_duration_days", "Label": "Pilot duration (days)", "FieldType": "number", "HelpText": "Suggest a short, practical horizon (e.g., 30–90 days) that allows measurement but limits cost.", "Required": true }, { "Key": "estimated_build_person_days", "Label": "Estimated build effort (person-days)", "FieldType": "number", "HelpText": "Include data engineering, modeling, integration, and validation effort. Provide conservative estimate.", "Required": true }, { "Key": "estimated_cost", "Label": "Estimated pilot cost (USD)", "FieldType": "number", "HelpText": "Include any third-party licenses, sensors, contractor time, and internal labor estimates.", "Required": true }, { "Key": "expected_roi_note", "Label": "How will ROI be estimated? (simple calculation)", "FieldType": "textarea", "HelpText": "Describe the calculation or assumptions (e.g., reduced downtime minutes * labor cost per minute - pilot cost).", "Required": true }, { "Key": "risk_rating", "Label": "Risk rating (1 = low, 5 = high)", "FieldType": "scale", "HelpText": "Operational, data, integration, or safety risk to run the pilot or to act on the twin's recommendations.", "Min": 1, "Max": 5, "Required": true }, { "Key": "success_criteria", "Label": "Pilot success criteria (check all that apply)", "FieldType": "checkbox", "HelpText": "Define measurable acceptance criteria that must be met to consider the pilot successful.", "Options": [ { "Value": "metric_improvement", "Label": "Primary metric meets or exceeds target" }, { "Value": "actionable_alerts", "Label": "Twin produces actionable alerts with acceptable false-positive rate" }, { "Value": "integrations_working", "Label": "Required integrations function reliably" }, { "Value": "operator_acceptance", "Label": "Operators/engineers accept the twin's outputs in trials" }, { "Value": "forecast_stability", "Label": "Model outputs are stable and explainable" }, { "Value": "cost_within_budget", "Label": "Pilot stays within estimated budget" } ], "Required": true }, { "Key": "acceptance_ready", "Label": "Do you currently meet the minimum of 3 success criteria above?", "FieldType": "yesno", "HelpText": "Answer yes only if at least 3 criteria are expected to be satisfied by the proposed pilot.", "Required": true }, { "Key": "go_no_go_recommendation", "Label": "Preliminary go / no-go recommendation", "FieldType": "radio", "HelpText": "Based on the plan and estimated ROI/risk, choose a preliminary recommendation. Final decision should be made after pilot results.", "Options": [ { "Value": "go", "Label": "Go to pilot" }, { "Value": "conditional_go", "Label": "Conditional go (address specific gaps first)" }, { "Value": "no_go", "Label": "No go (do not pilot now)" } ], "Required": true }, { "Key": "recommendation_rationale", "Label": "Recommendation rationale and required actions before pilot (if any)", "FieldType": "textarea", "HelpText": "Explain why you recommended this and list any concrete actions required before launching (e.g., add sensors, grant data access, schedule operator time).", "Required": true }, { "Key": "final_signoff_name", "Label": "Sign-off (name & role)", "FieldType": "text", "HelpText": "Person who will sign the final go/no-go after pilot completion.", "Required": false }, { "Key": "notes_and_next_steps", "Label": "Notes & next steps", "FieldType": "textarea", "HelpText": "Capture immediate next steps, meeting cadence, and who will prepare pilot artifacts (data extracts, integration tickets, model specs)." } ] }