#85 Software Digital Twins Boosting Reliability Through DevOps

How do simulations truly integrate into the world of digital twins—and what role do surrogate models and AI play in driving smarter design?In this episode, hosts Juliann Grant and Jonathan Scott continue the Digital Twin Series with a deep dive into simulation, featuring guest expert Shawn Freeman from Vias3D. With over 30 years of experience in CAE and simulation-driven product development, Shawn helps demystify how traditional CAE, surrogate modeling, and emerging technologies like AI are transforming how we design, manufacture, and operate products.🔍 Topics covered:Why traditional simulations alone aren’t enough for real-time digital twinsHow surrogate modeling helps speed up decision-makingThe four key components of simulation: inputs, outputs, model, and solverHow simulation results are stored, trusted, and integrated into PLM systemsOperational use cases, from vehicle design to in-flight aircraft assessmentsThe rising impact of AI in generating richer, faster simulation models🎧 Whether you're designing consumer products or managing aircraft performance, this episode gives you a comprehensive look at how simulation fits into the digital twin ecosystem.👉 Got questions or comments? Email us at [email protected] or comment on our latest post. Until next time—stay sharp.Music is considered “royalty-free” and discovered on Story Blocks.Technical Podcast Support by Jon Keur at Wayfare Recording Co.© 2024 Razorleaf Corp. All Rights Reserved.

In this episode, hosts Juliann Grant and Jonathan Scott are joined by Patrick Harrigan, VP of Partnerships at Caddi, to explore the transformative role of AI in unlocking the potential of unstructured data in manufacturing.While most conversations in digital engineering focus on structured data—PLM, ERP, and CAD—this episode dives deep into the massive (and often untapped) world of unstructured data: paper documents, legacy drawings, tribal knowledge, and more.💡 Topics Covered:What unstructured data actually means in a manufacturing contextWhy up to 80% of valuable data remains unused—and how AI is changing thatThe difference between systems of record and systems of insightHow AI is accelerating the conversion of historical documents and tribal knowledge into searchable, useful intelligenceReal-world applications for AI-powered insights—from reducing engineering inefficiencies to improving quality controlWhat makes manufacturing data uniquely challenging for general AI tools—and how purpose-built platforms are adaptingThe future of connected insights across structured and unstructured data domainsWhy “agentic AI” and human-in-the-loop workflows matter now more than ever🔧 Key Insight:AI isn’t just a buzzword—it’s a powerful tool for surfacing decades of buried knowledge and connecting data silos across the digital thread. Whether it’s improving design reuse, surfacing legacy quality fixes, or simply saving engineers from being “librarians,” the potential is vast.🎧 Listen now on your favorite podcast platform or watch on YouTube. 📩 Questions or feedback? Email us at [email protected] Sharp—and stay curious.Music is considered “royalty-free” and discovered on Story Blocks.Technical Podcast Support by Jon Keur at Wayfare Recording Co.© 2024 Razorleaf Corp. All Rights Reserved.

In this special 25th anniversary episode, we’re taking a trip down memory lane with Razorleaf’s CEO and co-founder, Eric Doubell. Hosts Juliann Grant and Jonathan Scott sit down with Eric to reflect on the pivotal moments, lessons learned, and guiding values that shaped Razorleaf’s journey from a scrappy startup to a global digital engineering leader.💡 In this episode, we cover:The founding story of Razorleaf — how an unexpected turn led to its creationBehind-the-scenes tales, including the surprising role 9/11 played in team formationLessons learned from growing a business with heart, integrity, and adaptabilityWhy being “people first” has driven Razorleaf’s culture and long-term succesThe evolution of the digital engineering landscape — and how Razorleaf has stayed aheadHow global growth has challenged and enriched the company’s perspectiveThe “hard things” Razorleaf chooses to take on — and why that matters for innovationWhat’s next for Razorleaf in an age of AI, cloud PLM, and multi-tenant systems🔥 Whether you’re an entrepreneur, PLM expert, digital engineering leader, or longtime Razorleaf partner, this episode offers insight into building a resilient, values-driven company in a rapidly changing tech world.📩 Have a question for Eric or the team? Email us at: [email protected] 👍 Like this episode? Subscribe and leave a review on your favorite platform, and follow Razorleaf on social media.🔗 Learn more at razorleaf.comMusic is considered “royalty-free” and discovered on Story Blocks.Technical Podcast Support by Jon Keur at Wayfare Recording Co.© 2024 Razorleaf Corp. All Rights Reserved.

In this episode of Stay Sharp in Digital Engineering, we go beyond the product digital twin and dive into the transformative world of virtual twins for manufacturing processes. Juliann and Jonathan are joined by Kevin Sullivan of Dassault Systèmes to explore how leading manufacturers are using process twins to simulate, optimize, and future-proof their factory operations.You’ll learn:  ✅ The difference between digital twins and virtual twins  ✅ How process twins drive efficiency, lean manufacturing, and pull-based production  ✅ Real-world use cases from bottling lines to automotive to greenfield factory builds  ✅ Why simulation matters more than ever in high-speed, high-volume production  ✅ How virtual twins support sustainability, supply chain resilience, and even human ergonomicsWhether you’re designing a new facility or trying to modernize an existing one, this episode will give you practical insights on how to use virtual twins to cut costs, reduce risk, and increase adaptability.Topics Discussed:What sets a “virtual twin” apart from a standard digital twinExamples of product vs. process value in different industriesPlanning new factory builds with simulation-first strategiesCreating human and robot twins for safety and efficiencyIntegrating sustainability into manufacturing process designA roadmap for getting started and scaling virtual twin technologyResources  Contact: Have questions or want to connect with our guest? Drop us a line at 📧 [email protected]📌 Don’t forget to like, subscribe, and leave a review on your favorite podcast platform!Music is considered “royalty-free” and discovered on Story Blocks.Technical Podcast Support by Jon Keur at Wayfare Recording Co.© 2024 Razorleaf Corp. All Rights Reserved.

In this episode of Stay Sharp in Digital Engineering, hosts Juliann Grant and Jonathan Scott welcome back Dr. Patrick Hillberg for his fourth appearance on the show. A professor and thought leader in PLM, systems thinking, and digital transformation, Dr. Hillberg joins the conversation to explore powerful and practical use cases for digital twins across industries.From Hollywood film sets and football fields to harbor cranes, commercial airliners, and collapsed buildings, this episode dives into how digital twins—and more importantly, digital threads—are being used to simulate, diagnose, and even prevent catastrophic events.🔍 Highlights from the Episode:How Apollo 13's analog twin scene inspired a new way to understand digital twin valueReal-world failure analysis: a Texas harbor crane collapse and the missed opportunity for a front-running simulationThe tragic 737 door plug and MAX incidents—and what could have been prevented with a robust digital threadDigital twins in consumer tech: how your car app may already be a sparse but effective digital twinWhy insurance companies might lead the charge in demanding front-running simulations for risk mitigationA strong case for designing your digital thread before you build your productDr. Hillberg also walks us through the six foundational pillars of product lifecycle management, originally laid out by Michael Grieves, and reframes them as essential elements of a functioning digital twin ecosystem.Whether you're an engineer, innovator, or executive, this episode challenges you to rethink how you capture, use, and respond to real-time data—and how digital twins can be your most valuable asset in designing for safety, efficiency, and accountability.🎧 Tune in to hear:The critical difference between a digital twin and a digital threadWhy sparse twins can still deliver massive valueHow front-running simulations could prevent billion-dollar mistakes—and save lives👉 Got a question for Patrick? Want to suggest a future topic? Leave us a comment or send an email to [email protected] is considered “royalty-free” and discovered on Story Blocks.Technical Podcast Support by Jon Keur at Wayfare Recording Co.© 2024 Razorleaf Corp. All Rights Reserved.

What really goes into building a digital twin that delivers value?In this episode, Juliann and Jonathan welcome industry veteran Dan Miklovic to unpack how digital twins are evolving to encompass not just the product, but the process that creates it. With over 50 years in manufacturing—from the plant floor to analyst firms like Gartner—Dan brings unparalleled insight into what it takes to build accurate, actionable digital twins in today’s fast-moving industrial landscape.You’ll learn:The difference between MES, MOM, and IIoT—and why they matterHow digital twins connect to digital threads (and why it’s more of a tapestry)Why capturing how something was built is as important as what was builtThe critical role of process data in enabling agility, quality, and sustainabilityHow digital twins empower smarter decision-making in a world of AI, tariffs, and supply chain disruptionWhether you work with engineered-to-order products or high-volume manufacturing, this conversation will change how you think about digital twins—from static snapshots to living, breathing models of your operation.🔧 Topics Covered:MES vs MOM vs IIoT: Definitions and real-world relevanceThe evolution from hardwired sensors to cloud-connected IIoTCapturing the “as-built” truth for compliance and qualityUsing process twins for optimization and adaptabilityHow Industry 4.0 and 5.0 shape digital manufacturing strategiesWhy accurate, timely data is foundational for AI and ML applications📨 Have a question for Dan or the Razorleaf team? Email: [email protected]📺 Watch on YouTube or subscribe wherever you get your podcasts.Until next time—work hard, and stay sharp.Music is considered “royalty-free” and discovered on Story Blocks.Technical Podcast Support by Jon Keur at Wayfare Recording Co.© 2024 Razorleaf Corp. All Rights Reserved.

In this episode of Stay Sharp in Digital Engineering, hosts Juliann Grant and Jonathan Scott continue their Digital Twin series—this time focusing on software digital twins. While hardware digital twins often dominate the conversation, software-based twins are playing an increasingly vital role in modern engineering and manufacturing.Juliann and Jonathan break down what software digital twins actually are (hint: it’s not always straightforward), where they live in the tech ecosystem, and how they power everything from simulation and testing to configuration management and DevOps pipelines. They also explore how these twins are used differently depending on whether software is the product or part of a larger physical system—like a smart refrigerator or a modern aircraft.You’ll learn about:The difference between digital twins for software-only products vs. cyber-physical systemsHow DevOps and Application Lifecycle Management (ALM) tools support digital twin environmentsThe role of emulators and virtual machines in simulating real-world software performanceWhy configuration management is critical to successful digital twin implementationHow industries like aerospace and automotive use software digital twins for reliability and safetyKey Quote: "Software digital twins may not always be visible—but they're absolutely vital when lives, safety, and product performance are on the line."💡 Want to join the conversation or request a follow-up episode? Email us at [email protected] or leave a comment wherever you listen.Music is considered “royalty-free” and discovered on Story Blocks.Technical Podcast Support by Jon Keur at Wayfare Recording Co.© 2024 Razorleaf Corp. All Rights Reserved.

In this episode, Juliann and Jonathan dive into insights from the CIMdata PLM Roadmap and PDT Conference, held May 7–8 in Tysons Corner, VA. With this year’s theme—“PLM’s Integral Role in Digital Transformation: From Strategy to Execution”—they reflect on the event’s most powerful takeaways and presentations that explore how PLM can evolve from a tech initiative to an enterprise-wide business enabler.💡 What you'll learn in this episode:Key trends shaping PLM in 2025, from digital threads to AI readinessWhy clear business cases and executive sponsorship are essential for PLM successThe critical (but often overlooked) role of data in transformation strategiesReal-world insights from companies like Airbus, Boeing, Hollister, and Hitachi EnergyA behind-the-scenes look at the Aerospace & Defense PLM Action Group’s findings on digital thread use casesHighlights from Dr. Martin Eigner’s 40-year retrospective on PLM evolutionWhether you're an engineering leader, IT professional, or digital transformation strategist, this recap offers practical frameworks and honest reflections to help your PLM strategy drive real business outcomes.🔗 Resources & Mentions:CIMdata & Eurostep PLM Roadmap/PDT ConferenceA&D PLM Action Group Digital Thread ResearchFeatured Speakers: Dr. Martin Eigner, Caroline Gustafson (Hitachi Energy), Stacy Burgart (Hollister), Kenny Swope (Boeing)📍Next stop: PLM Roadmap Europe – November in Paris – Learn more at cimdata.comMusic is considered “royalty-free” and discovered on Story Blocks.Technical Podcast Support by Jon Keur at Wayfare Recording Co.© 2024 Razorleaf Corp. All Rights Reserved.

In this episode of Stay Sharp in Digital Engineering, hosts Juliann Grant and Jonathan Scott are joined by renowned PLM thought leader and sustainability advocate, Jos Voskuil, co-founder of the PLM Green Global Alliance.Together, they unpack the evolving role of sustainability within the world of Product Lifecycle Management (PLM) and digital engineering. From the European Green Deal to the growing importance of lifecycle assessment (LCA), this episode explores how environmental impact is shaping how products are designed, manufactured, and maintained.🔍 Topics Covered:What sustainability really means in the context of PLMRegulatory drivers like RoHS, REACH, and the EU Digital Product PassportThe shift from hazardous material tracking to full carbon reportingWhy “right to repair” and circular economy models are gaining tractionHow the product-as-a-service model transforms business sustainabilityPractical steps for manufacturers to begin measuring environmental impactReal-world examples of data-driven PLM and the use of digital twinsTools and databases supporting sustainability analysis (e.g., EcoInvent, LCA, AI-driven platforms)The importance of model-based systems engineering and connected data🌍 Key Insight: Sustainability is no longer a side concern—it’s becoming a central factor in product innovation and compliance. And while regulations are often the spark, digital transformation is the fuel that helps companies prepare, respond, and lead.📩 Got questions or feedback? Email us at [email protected] or drop a comment wherever you listen.Music is considered “royalty-free” and discovered on Story Blocks.Technical Podcast Support by Jon Keur at Wayfare Recording Co.© 2024 Razorleaf Corp. All Rights Reserved.

Hosts Juliann Grant and Jonathan Scott sit down with Bob Maffia of BAE Systems to unpack what it really takes to manage large-scale PLM systems. From supporting thousands of users to navigating digital engineering, Bob shares practical lessons from the front lines.💡 HighlightsReal-world challenges of enterprise PLM at scaleBalancing customization with vendor capabilitiesStrategies for digital engineering: start small, stay agile, engage stakeholders earlyAdvice for vendors on openness and smoother upgrades📩 Get in TouchHave a question or want to connect with Bob? Email us at [email protected]🎧 Follow UsSubscribe on your favorite podcast platform or YouTube—and as always, stay sharp!Music is considered “royalty-free” and discovered on Story Blocks.Technical Podcast Support by Jon Keur at Wayfare Recording Co.© 2024 Razorleaf Corp. All Rights Reserved.