The Role of Simulation and Digital Twins in Enhancing Mechanical Production Efficiency: A Systematic Review

Year : 2025 | Volume : 15 | Issue : 02 | Page : 31 36
    By

    Shubham Mishra,

  1. Research Scholar, Department of Electrical Engineering, Jaipur Engineering College & Research Centre, Jaipur, Rajasthan, India

Abstract

In the evolving landscape of smart manufacturing, simulation technologies and digital twin (DT) systems have emerged as pivotal tools for enhancing the efficiency, agility, and sustainability of mechanical production processes. This systematic review investigates how the integration of simulations and DTs contributes to performance improvements across various stages of mechanical manufacturing—ranging from design and process optimization to predictive maintenance and real-time monitoring. While simulations provide the ability to model, test, and optimize production scenarios virtually, DTs create a synchronized digital counterpart of physical systems that continuously evolves through real-time data exchange. The review synthesizes findings from a wide range of peer-reviewed literature published over the past decade and categorizes the technological enablers, use-case scenarios, benefits, and implementation challenges. The study highlights how DTs are increasingly used to improve decision-making, reduce downtime, extend asset life, and support energy-efficient operations. It also explores the role of simulations in reducing the need for costly trial-and-error in physical settings, enhancing system flexibility, and improving throughput in mechanical production lines. However, the review also notes key challenges such as high deployment costs, the need for standardization, data integration complexities, and cybersecurity risks, which currently limit the widespread adoption of these technologies—particularly among small and medium-sized enterprises (SMEs). Despite these hurdles, the future outlook remains promising, with advances in artificial intelligence (AI), edge computing, and industrial Internet of Things (IoT) paving the way for more intelligent, scalable, and accessible digital manufacturing ecosystems. By critically analyzing the current state of simulation and DT technologies, this review aims to guide researchers, practitioners, and industrial stakeholders toward more effective adoption strategies. The study concludes by identifying pressing research gaps and outlining future directions that will further enable smart, resilient, and efficient mechanical production systems under the Industry 4.0 framework.

Keywords: Digital twins, simulation, mechanical production, Industry 4.0, predictive maintenance, smart manufacturing

[This article belongs to Journal of Production Research & Management ]

How to cite this article:
Shubham Mishra. The Role of Simulation and Digital Twins in Enhancing Mechanical Production Efficiency: A Systematic Review. Journal of Production Research & Management. 2025; 15(02):31-36.
How to cite this URL:
Shubham Mishra. The Role of Simulation and Digital Twins in Enhancing Mechanical Production Efficiency: A Systematic Review. Journal of Production Research & Management. 2025; 15(02):31-36. Available from: https://journals.stmjournals.com/joprm/article=2025/view=224398


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Regular Issue Subscription Review Article
Volume 15
Issue 02
Received 10/07/2025
Accepted 25/07/2025
Published 06/08/2025
Publication Time 27 Days
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