In the contemporary industrial landscape, technological innovation is a strategic lever for increasing efficiency and competitiveness. Among the most promising solutions are some that we have not heard much about yet, but which we are sure will be talked about a lot already in the coming months: predictive maintenance and digital twins. These technologies that, when properly integrated with each other and with AI and augmented and virtual reality, can revolutionize production and management processes.
What are digital twins or digital twin
A digital twin (or digital twin) is a virtual replica of a physical asset, such as a plant, machine, or entire production line. This digital model is not static, but evolves in real time thanks to data collected by sensors deployed on the physical asset. This data includes parameters such as vibrations, temperatures, velocities and workflows, allowing the asset’s performance to be monitored, analyzed and optimized continuously. A practical example of using digital twins is in a wind power plant: each turbine can be monitored through its digital twin to predict failures, optimize power production and reduce downtime.
What is predictive maintenance
Predictive maintenance leverages data generated by digital twins to anticipate malfunctions and reduce costs associated with sudden failures. Unlike traditional maintenance (corrective or scheduled), predictive maintenance intervenes only when necessary, relying on advanced data analysis and artificial intelligence models. A concrete application can be found in the railway industry: companies can monitor the wear and tear on tracks or train components in real time, intervening only when parameters exceed a critical threshold. This approach not only reduces costs, but also improves safety and service reliability.
The role of ultra-broadband
In order for predictive maintenance and digital twins to spread widely, an ultra-broadband network is essential. Data transmission from the sensors to the cloud infrastructure must be real-time, with minimal latency and high throughput. A fiber connection provides the stability needed to handle large volumes of data, while low latency is essential for critical applications, such as those involving manufacturing plants or transportation systems.
Application horizons
Technological evolution and the availability of advanced network infrastructure are paving the way for increasingly sophisticated scenarios. Future applications include:
- Precision agriculture: the use of digital twins to monitor the life cycle of crops by analyzing weather data, soil quality and satellite images. This will optimize crop yields and reduce the use of resources such as water and fertilizer.
- Smart cities: digital twins for managing urban infrastructure, such as water networks, transportation systems or buildings. For example, a city could use digital models to optimize electricity distribution during peak hours.
- Health care: hospitals and research centers could create digital twins of patients to simulate treatments and surgeries, reducing risks and improving clinical outcomes.
The apps that will revolutionize the world of work
As we have already mentioned, high-capacity network infrastructure is now the first and indispensable condition for being able to talk about innovation in the world of work and its processes. Ultrabroadband, however, is not “limited” to enabling flexible ways of working such as smart working; it also opens the door to advanced technological solutions that are revolutionizing several areas of operation, making it possible, and indeed convenient, to work remotely on functions that until now we have been used to link to the impossibility of this prospect, such as network technicians. The smart working we are most commonly accustomed to thinking of is that of people working at their PCs, on documents shared in the cloud, collaborating with colleagues in online meetings. Today, however, we are taking a significant step forward in the development of new ways of working remotely, thanks, for example, to the use of immersive technologies such as virtual and augmented reality, which, by integrating with artificial intelligence and digital twins, are transforming, indeed revolutionizing, the ways in which technical work is done. Imagine, for example, the scenario in which field workers, such as installers or network maintainers, can devote a couple of hours to an intervention instead of two days away. With the integration of digital twins and artificial intelligence (AI) making remote work possible and convenient for network technicians, managing predictive and assisted maintenance interventions on complex infrastructure is already a reality today.
Practical scenario: predictive maintenance and remote support for a technician
A company operating a fiber optic network uses a digital twin to replicate virtually every segment of the physical infrastructure, including cables, joints and active equipment. Using IoT sensors distributed along the network, the digital twin continuously receives data on the state of the infrastructure, such as temperature, vibration or any micro-damage. An AI system analyzes this data in real time to identify anomalies and predict impending failures. When the AI detects a risk, it generates an optimal action plan and communicates it to technicians. The experienced technician, operating remotely, can visualize the affected area on the digital twin and simulate repair operations, anticipating any critical issues.
Assisted remote intervention: visors and AI
The field technician is guided by the remote operator through AR viewers. Thanks to AI integration, the viewer projects optimal directions directly onto the actual equipment: for example, cable splice points or parameter adjustments, calculated from the data collected. The remote technician, in turn, uses the doigital twin to monitor the progress of the intervention in real time and make any changes.
What are the benefits for companies?
Key benefits for companies that will integrate technologies such as digital twins and augmented reality viewers include:
- efficiency: AI optimizes interventions, reducing resolution time and costs associated with errors or repeated interventions;
- travel savings: thanks to digital twin and assisted driving, the number of field technicians can be drastically reduced and local staff with basic skills can be sent;
- ongoing training: remote technicians gain experience analyzing real data and handling complex interventions, without the need to travel;
- sustainability: less travel means a smaller carbon footprint and environmental impact of business operations.
This approach not only makes remote work more feasible for experienced technicians, but also increases overall operational effectiveness, transforming maintenance from a cost to a strategic element for the company. Here we have cited the example of an operator in our industry, fiber optics, but we can easily imagine the same dynamics applied to other scenarios. The business world can really benefit impressively for everyone from the proper integration of new technologies.
Predictive maintenance and digital twins
Despite the potential, the implementation of these technologies presents some challenges, such as:
- data management: the amount of information generated by sensors requires advanced systems for storage and processing. Hybrid solutions, combining public and private clouds, can be an effective compromise;
- staff training: the adoption of digital twins and predictive maintenance requires specialized skills, not only technical but also managerial. It is essential to invest in training people who can interpret data and collaborate with technology partners.
Ultra broadband and integrated technologies for the future of work
Predictive maintenance and digital twins are not only an opportunity for companies to improve their performance, but also a key step toward a more sustainable and digital future. Supported by an ultra-broadband network, these technologies can transform sectors such as industry, agriculture, healthcare, and infrastructure, helping to create a connected, efficient, and innovative ecosystem. Investing in these solutions today means not only optimizing the present, but also preparing for a tomorrow in which the integration of the physical and digital worlds will be the key to success.