Modern automation systems generate enormous amounts of operational data. Yet in many manufacturing environments, visibility into how the process actually occurred remains limited.
High-speed operations, compact work envelopes, advanced tooling geometries, and real-time process variability make diagnosing production behavior increasingly difficult.
Every product moving through an automated system experiences a unique process instance influenced by temperature, pressure, voltage, material variation, and machine condition.
TwinSync™ is a process monitoring and optimization platform from Valiant TMS that connects physical automation systems to a synchronized digital representation of the manufacturing process.
By capturing high-frequency operational data and mapping it directly to product geometry, TwinSync™ enables engineering and production teams to observe, analyze, and continuously improve automation performance across the entire production lifecycle.
The result is automation that becomes more transparent, more controllable, and capable of continuous improvement over time.
Traditional automation monitoring focuses primarily on outcomes:
While these indicators are important, they rarely explain why a process behaved the way it did.
TwinSync™ focuses on the process itself.
By capturing detailed operational data within a synchronized digital twin environment, engineering teams gain visibility into how every operation actually occurred, not simply whether it succeeded.
This deeper visibility supports the entire automation lifecycle:
Processes can be viewed, recorded, and shared without entering the production cell, allowing engineering, maintenance, and quality teams to collaborate safely and efficiently.
By improving visibility into process behavior, manufacturers can accelerate troubleshooting, reduce downtime, and shorten the time required to stabilize new production launches.
TwinSync™ creates a real-time digital twin of an automated system and overlays process data directly onto product geometry.
Engineers can observe the process from perspectives that would otherwise be impossible, including the precise viewpoint of the tool or applicator performing the operation.
TwinSync™ also enables picture-in-picture process views, allowing engineers to observe operations from inside confined automation spaces or from the perspective of the process applicator itself.
This capability enables:
Because the process can be reviewed digitally, teams can investigate issues without stopping production or entering the automation cell.
Geometry layers can be toggled on or off, allowing engineers to isolate process behavior without unnecessary visual complexity.
TwinSync™ connects automation equipment, process data, and digital visualization into a unified process intelligence platform.
The system operates across four integrated layers.
TwinSync™ connects directly to the physical automation environment, collecting operational data from production equipment, including:
This data reflects the real conditions under which every product is manufactured.
High-frequency operational data is captured during each process cycle and synchronized with the digital twin environment.
Each moment in the process is recorded as a DataNode, linking process parameters to the exact spatial location and tool orientation at that point in the operation.
This creates a structured record of how the process actually occurred.
DataNodes are organized into DataMaps, which represent the complete process history for each product instance.
These DataMaps allow engineering teams to:
This creates a manufacturing data model that reflects both process behavior and physical geometry.
TwinSync™ presents process data through an interactive digital twin environment that allows engineers to:
This unified view enables faster diagnostics, better decision making, and continuous process improvement.
At the core of TwinSync™ is the DataNode.
Each DataNode represents a moment in the process where information was captured, including the precise three-dimensional location on the product and the orientation of the process tool relative to the part.
Instead of storing process values as isolated data points, TwinSync™ associates operational data with exact physical locations in the manufacturing operation.
DataNodes capture information such as:
This creates a structured record describing not only what happened, but where and how it happened within the process.
DataNodes are organized into DataMaps, an intelligent point cloud of process information plotted across the product digital twin.
Each DataMap represents a complete process cycle.
Capabilities include:
Selecting a row in the data table highlights the corresponding point on the digital twin, while selecting a point on the model reveals the associated process data.
This direct connection between engineering data and physical geometry allows teams to diagnose issues faster and better understand how process behavior affects product quality.
A new DataMap is generated for each machine cycle and permanently associated with the unique product instance moving through production.
This provides a complete digital process record for every manufactured part.
TwinSync™ enables:
DataMaps can also contain the DataMaps of assembled components, allowing traceability to follow the product through multiple manufacturing stages.
This hierarchical structure provides powerful visibility into how individual component processes contribute to the performance of the final assembly.
Manufacturing teams often diagnose problems only after a failure occurs.
TwinSync™ enables a shift from reactive troubleshooting to proactive process control.
Critical areas of a process can be defined directly within the DataMap, allowing dynamic tolerance windows to be applied during production.
A master DataMap can also be used as a reference process signature, allowing production cycles to be compared against expected behavior during runtime.
This provides:
TwinSync™ can also integrate with automated equipment verification routines that confirm machine alignment or process readiness before production begins.
The result is greater process stability, improved quality, and reduced downtime across the life of the automation system.
TwinSync™ stores structured process records with an efficient file footprint, allowing years of production data to be retained economically.
This long-term visibility enables powerful analysis capabilities:
Because DataMaps are not tightly coupled to proprietary product geometry, process data can be shared internally or with trusted partners without exposing sensitive design information.
Manufacturers gain the ability to learn from production history and continuously refine their processes over time.
TwinSync™ supports manufacturing programs from initial system development through years of production operation. By capturing and organizing detailed process data, the platform helps engineering teams understand and improve automation performance at every stage of the system lifecycle.
During system development and simulation, TwinSync™ enables engineers to understand process geometry and verify how tools interact with the product.
During system commissioning and production launch, TwinSync™ provides detailed visibility into process behavior, helping teams identify root causes quickly and stabilize production faster.
During normal production, TwinSync™ continuously captures process data and compares production cycles against reference process signatures to detect anomalies and maintain process stability.
Over time, accumulated DataMaps allow engineering and maintenance teams to analyze long-term trends, investigate quality events, and refine process performance.
Artificial intelligence systems require structured, well-organized process data.
TwinSync™ generates exactly that.
By capturing detailed process signatures tied to product geometry and manufacturing conditions, the platform creates a strong foundation for predictive analytics, machine learning applications, and future smart factory initiatives.
TwinSync™ prepares manufacturing systems for the next generation of data-driven production optimization.
TwinSync™ integrates directly with automation systems, process equipment, and industrial control infrastructure.
Operational data can be collected from sources such as:
This data is synchronized with the digital twin environment alongside normal production operation.
TwinSync™ can be deployed as part of new automation installations or integrated into existing production systems.
TwinSync™ is designed to operate within real manufacturing environments and alongside established automation systems.
The platform supports the practical requirements of modern production programs, including:
TwinSync™ allows manufacturers to introduce advanced process visibility without disrupting established production operations.
TwinSync™ supports a wide range of automated manufacturing processes, including:
The platform provides process visibility across nearly any automated manufacturing operation where performance data can be captured.
TwinSync™ — 3D model showing robotic washer applicationIn production environments where digital twin DataMapping was used to benchmark and refine automated wash processes, system efficiency improved by 5–40 percent, with optimization performed remotely across multiple facilities.
These improvements were achieved by identifying process inefficiencies, refining process paths, and improving coverage consistency across multiple product variants.
Traditional automation systems are designed to perform a fixed process.
TwinSync™ enables automation systems to evolve with operational data — allowing manufacturers to continuously refine process performance, improve quality, and extract greater value from their automation investment over time.
By combining real-time process visualization, structured operational data, and lifecycle traceability, TwinSync™ provides manufacturers with deeper insight into how automated systems actually perform.
The result is faster troubleshooting, stronger process control, better production outcomes, and automation systems that continue to improve long after installation.