Pratt & Whitney has found a new and improved way to tackle their Measure phase using process modeling and simulation. Essentially, they’ve created a digital twin of their production process, a living replica of the existing system.

• Creating a model forces the modeler to learn how the system operates

• Modeling forces the process experts to accurately describe the system

• Modeling sparks questions otherwise never asked

Pratt & Whitney has also used their digital twin to refine the Analyze phase in the DMAIC process. Analysis typically involves running the numbers to find patterns and gain understanding. However, with a digital twin Pratt & Whitney examines any aspect of their production process in detail and see the behaviors and causes of any issues.

During the Improve phase a digital twin allows a company to make changes to its production process and see the potential consequences of those changes before implementing them in the existing system. Using a digital twin you can do the following:

• See and remove non value adding activities

• Remove Waste, and apply lean guidelines

• Address current state issues

• Enhance process dynamics

• Conduct quantitative optimization

Overall, incorporating process simulation into the Improve phase of Six Sigma can help a company to dramatically improve its process.