AI-driven digital twins are emerging as a significant advancement in manufacturing, allowing real-time visualization of entire production lines instead of just individual machines. Indranil Sircar, the global chief technology officer for Microsoft’s manufacturing and mobility sector, highlights that this technology equips manufacturers with broader insights, moving away from isolated monitoring practices.
For instance, a digital twin of a bottling line can gather one-dimensional telemetry from the shop floor, two-dimensional enterprise data, and three-dimensional immersive modeling into a unified operational view. This integration aims to enhance efficiency and minimize costly downtime, which in some high-speed industries can reach rates of 40%, according to Jon Sobel, co-founder and CEO of Sight Machine, an industrial AI company collaborating with Microsoft and NVIDIA. By using digital twins to track micro-stops and quality metrics, companies can identify targeted improvements, potentially saving millions in productivity without interrupting ongoing operations.
The adoption of AI in manufacturing is on the rise, with Sircar estimating that about 50% of manufacturers are currently utilizing AI in their production processes. This marks an increase from 35% reported in a 2024 MIT Technology Review Insights survey. Notably, larger manufacturers, those with revenues exceeding $10 billion, lead the way, with 77% already deploying AI applications.
Sobel remarks that manufacturing, often viewed as lagging in digital technology, may, in fact, be well-positioned to leverage AI effectively. The discussion continues regarding how this sector can transform data into actionable insights to improve operations and productivity.
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Source: https://www.technologyreview.com/2025/11/19/1128067/scaling-innovation-in-manufacturing-with-ai/