Transform Your Business Flawlessly

Create digital twin, then use the twin to create best solutions, using less time, high confidence, and fewer resources
According to recent research 70%* of transformation projects fail, but that’s not just new research. Jack Welch, then CEO of GE, said the same thing in 2001. He identified and corrected the problem and became one of the most successful leaders in the world. Make sure you understand the real problem.

There is no better way to uncover the issues facing a complex system than by creating a digital twin, a model of how the system works. Building the model requires you to ask questions you have never considered. When you completed the process, you have an in-depth understanding of how the system works.

“I wish I had this product the day I took over my department. Creating a model requires you to uncover what is really happening – you learn timing, resources requirements and dependencies that can’t be shown with data or flowcharts.”


Capture knowledge by simulating scenarios that test limits, constraints, relationships, tradeoffs, and process “drivers.”

1. Determine the TAKT time or Turn-around time

2. Evaluate the current state performance concerning target metrics

3. Determine the total process capability – Understand the source and result of variability

4. Determine “rolled throughput yield” and characterize the contributors

5. Identify and evaluate any “batching” in the process

6. Evaluate activity and resource loading

military truck - process improvement

“It makes me laugh when I hear “experts” talk about process transformation without understanding the current system – it’s’ like getting remarried before understanding why the first marriage failed. But, using a digital twin requires a deep understanding of the current system’s process, drivers, variability, and capability. You can now see what is causing problems. Then and only then do you have the understanding to make meaningful changes.”

Unless the process is “right,” no other modification will work. Vision, leadership, sponsorship, culture change, and various approaches are essential, but without a refined process, you’re just putting “lipstick on a pig.” Modern systems are too complex and intertwined to guess. You must have a method of evaluating the merit of a change before investing, or probability says you will fail.

“We prepare cars for export. Many changes proved fruitless. Because of low production, our unit was on the verge of being shut down. After building a model of the entire process, I could see the interactions of all departments. Problems became obvious. Combining many ideas created a production rate increase greater than management thought possible. The digital twin allowed our unit to transform the process into the top unit in our company.”

Determine proactive health metrics for your process. These include making SMART metrics -- Specific, Measurable, Assignable, Relevant, and Timely.

Determine how, where, and when the process monitoring occurs (control plan). For example, reviews might include both elapsed time and volume changes.

Establish the standard to measure against – Run the digital twin at different rates and observe the inflection points.

air craft engine - process optimization

“The digital twin became an integral part of the control plan. The model was a flexible document expanding and contracting with business rate changes. Throughput time, variability, resource utilization, and other metrics evaluated against the model during reviews showing unauthorized changes that needed correction.”

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“The process is perfectly designed to produce the exact results it’s producing. If you don’t like the results, fix the process.” – Edwards Deming

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