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Digital Twin

Twice the machine - Half the work!

Harnessing the Power of Digital Twin!

In today’s data-intensive industrial landscape, achieving operational excellence requires more than traditional systems. Digital twin technology is revolutionizing how manufacturers operate by creating virtual replicas of physical systems that reflect real-world performance, behavior, and conditions through live data and analytics.

We deliver full-spectrum digital twin services that empower U.S. industries to design, simulate, monitor, and optimize their operations across the entire lifecycle. From detailed mechanical modeling to IoT-driven dashboards, our solutions support smarter decisions and more resilient systems.

Digital Twin in Manufacturing

Why do you need Digital Twin?

Accelerate design and manufacturing cycles with real-time feedback
Detect issues early to minimize rework and avoid failures
Enable predictive maintenance and reduce downtime
Make faster decisions through remote monitoring and analytics
Maximize performance across design, production, and operation

Why simulate in silos when you can synchronize with the real world?

Our digital twin solutions go beyond static models—merging real-time operational data with high-fidelity simulations to optimize your processes and product designs. From factory floors to field assets, MNES enables intelligent, data-driven control of your physical systems. For enhanced simulation before deployment, explore our Plant Simulation Services.

Our CapabilitiesMNES offer digital twin technology built for scalability and precision

  • Real-Time Monitoring – Connect IoT data streams with live performance dashboards
  • Predictive Maintenance – Use analytics to forecast breakdowns and service needs
  • Plant Simulation – Virtually replicate logistics, workflows, and machine behavior
  • Performance Optimization – Run “what-if” tests to fine-tune output and throughput
  • Behavior Modelling – Capture control logic, feedback systems, and motion patterns
  • Integration – Seamlessly connect with SCADA, MES, ERP, and cloud systems

Our Custom SolutionsTailored for automotive, energy, pharma, and discrete manufacturing

  • Our mechanical design and simulation tools include:
    • 3D Modeling | Assembly & Sheet Metal Design | Tolerance Analysis
    • Siemens NX | SolidWorks | ANSYS | ThingWorx | Azure IoT | AutoCAD
    • PLM tools like Teamcenter, Windchill | Industrial Protocols: OPC UA, MQTT

Software Expertise

  • Siemens Plant Simulation
  • NX ANSYS, ThingWorx, Azure IoT AutoCAD
  • SolidWorks, Creo Teamcenter, Windchill
  • OPC UA, MQTT, REST APIs

FAQs

1. What is a Digital Twin?

Digital twin is a real-time virtual replica of a physical asset, updated using live data. Through digital twinning, it helps simulate, monitor, and optimize system performance across its lifecycle.

2. How does a digital twin work in manufacturing?

In manufacturing, a digital twin mirrors a machine or production line by integrating live data from sensors and control systems. This enables real-time monitoring, predictive maintenance, and process optimization, ultimately reducing downtime and increasing productivity.

3. Can digital twin technology be integrated into existing systems?

Yes. MN Engineering Solutions specialize in integrating digital twin solutions with legacy systems, PLCs, SCADA, MES, and ERP platforms. Our team ensures smooth connectivity and data flow between physical assets and digital models.

4. Do I need IoT infrastructure to implement a digital twin?

While IoT devices enhance digital twin functionality by enabling real-time data collection, we also offer solutions that can start with historical data or simulation-based modeling, gradually evolving into real-time digital twins as IoT capabilities are added.

5. What industries benefits most from digital twinning?

Industries such as automotive, pharma, energy, electronics, and aerospace see strong ROI.

6. How long does digital twin software and implementation take?

Typically, 4–8 weeks depending on complexity and integrations.

Let’s start your project to be realized.

We’re committed to helping you build smarter, more adaptive systems. Whether you’re designing the next-gen machine or upgrading factory intelligence, MNES is your partner in digital transformation.

Lets Start

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Naresh Arunagiri

Naresh Arunagiri has several years of extensive experience in engineering services concentrating in Research and Development (R&D), New Product Development (NPD), lean manufacturing, work holding design, process & product optimization, production automation in the Truck & Trailer, Life science, and industrial machinery.

Naresh has extensively spent the last decade working in the truck and trailer industry in multiple companies in designing their walk-in-vans and trailer bodies with the focus on supporting them in different areas like,

• Body design (Body in white)
• Validating design based on FMVSS and DOT standards
• Light body EV vehicle designs
• Automotive electronics

He was instrumental in bringing out the first-in-class last-mile delivery electric vehicle and the fully electric campus shuttle bus to the market.

In the area of automation, Naresh was part of the team that designed and implemented the “Factory of the future” for one of the largest mattress manufacturing companies in the globe. This entailed designing a single flow layout aided by world-class technology of AGVs, Industrial Robots, and Cobots. His exceptional exposure to Technical sales and Application engineering in various industries, has been a great asset to MN Engineering Solutions.

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Madhan Kumar Paramahamsan

Madhan Kumar Paramahamsan has worked for 23 years as an engineering product lead with several well-known companies like Morgan Olson, Leser Gmbh., Pratt & Whitney, Hayssen Sandiacre, Thomas & Betts Inc, Cummins Inc, Babcock & Wilcox & Keld Ellentoft in multiple geographies, and diverse projects.

Performed across multiple challenging roles engineering domains in advanced design and validation, technical advice & consulting to teams in industries like Automobile, Aerospace, Packaging Industry, Defence, Infrastructure & Utilities (I&U), etc. Madhan has solid knowledge and years of experience with the I&U industry and also contributed significantly in the area of research & development.

Madhan’s keen interest in design and engineering paved way for certifications of all the major CAD/Simulation tools. The expertise in the years of design, fabrication, and engineering experience has been the key in leading Madhan to make MN Engineering Solutions one of the front-runners in the engineering services and solutions with a team of par excellence and with the largest supply chain management in the industry.

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Senthil Kumar Deivasigamany

Accomplished serial entrepreneur with a proven track record of building and growing businesses from scratch. Particularly adept at visioning and strategizing and most importantly, successfully executing on the vision. Experienced in multiple domains, including sales & marketing, HR, and operations with key skills in Organization Development and Sales Management.

Over the last three decades, he has had myriad experiences that reinforced the foundation to build businesses. The tenure as a Sales Engineer in Tube Investments and Product Manager in Sterling Holidays gave a strong footing in sales and marketing, spanning 10 years. During that time, he propagated the importance of strategy, discipline and process orientation in enriching the sales pipeline and improving conversion. A short stint at ABC Consultants enabled him to understand how to attract and retain the best talent available in the market across various domains.

In the last 20 years with Barry-Wehmiller, a consulting company offering solutions to the manufacturing & technology industries, he orchestrated the growth from 6 associates to many hundreds in roles including Project Manager, Operations Manager, Business Development, and Business Unit Head with complete P&L responsibility. During this period, he was responsible for starting and growing the technology practice. Since 2010, he has been solely responsible for global sales of Engineering Services for Barry-Wehmiller, growing the business from $4 million to over $23 million in a span of 4 years.

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Rohit Jani

Rohit Jani is a mechanical engineer with over 23 years of experience in the marketing industry. Rohit is the lead sales and business advisory member with MN Engineering Solutions. His unrelenting experience over the years in business development, sales, marketing, and operations, set-up businesses in a new market, and building sustainable partnerships. Also, Rohit’s expertise extends to QC and ISO compliance for industries, B2B Marketing, price negotiations across contracts, and project executions.

Rohit’s excellence in diverse business strategies and in-depth experiences for sales for IT and Engineering Services. He is key to interacting and bringing business clients to MN Engineering Solutions. Rohit’s professional career includes companies like Vetus, Barry Wehmiller, Barmag India, Sungrace Engineering, and NIR Cadtech.

Rohit has strong customer relationship building and networking capabilities, sourcing and vendor management, cross-selling of products across different markets. He is equipped with sound knowledge of IT tools, ERP and experienced in using modern marketing tools. Rohit works experience spans globally across the USA, China, Western Europe, Maldives, and Srilanka.

In Rohit’s career, he was awarded on many occasions as the ‘Best Sales Person of the Year’ and twice as the ‘Best Project Manager’ with Barry Wehmiller. Rohit is also a certified PDM Works Enterprise Implementation Professional and Solidworks professional.

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Krishnakumar Krishnan

Results-oriented professional with 30 + years of experience, proven knowledge of business consulting, business development, partnership development, client expectation management, Training and delivery management.

He managed global sales and marketing to position enterprise applications and services to mid-market manufacturing companies both in the US, India and Middle East markets. Likes to engage in roles that are around mentoring sales teams, develop a go-to-market strategy, building new partnerships, sales operation, training, and mentoring.

His expertise comes from building strategic partnerships & alliances, key account management, and customer relationship management.

Passionate about training, mentoring talent and developing empowered teams to deliver world-class service in addition to training teams in effective communication methodologies.Travelled extensively, able to appreciate different cultures, wide CXO network

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