5-4. EHS Risk Simulation in Factories Using Digital Twins

Digital twins are a transformative technology that can be used to predict and manage EHS (Environmental, Health, and Safety) risks by creating a real-time virtual replica of a factory or facility. While traditional risk assessments rely on historical data and periodic inspections, digital twins enable companies to grasp changes on-site instantly and prevent accidents and environmental issues before they happen.

1. How Digital Twins Are Used in EHS

Digital twins are built using data from IoT sensors and production management systems to create a virtual replica of a facility's equipment and processes. This allows for the real-time monitoring of various factors, including temperature, vibrations, noise, and exhaust gas concentrations, which leads directly to the early detection of anomalies and the identification of risk factors. In the EHS field, this technology can also be applied to simulate chemical leaks, analyze fire and explosion risks, and evaluate safety based on worker movements.

2. Practical Applications of Risk Simulation

Digital twins allow companies to conduct scenario-based risk assessments. For example, they can immediately simulate the impact of changing the amount of a chemical stored or altering temperature conditions to predict the probability and scale of an accident. It is also possible to visualize the risk of equipment failure due to aging and incorporate this into maintenance plans. Furthermore, reproducing evacuation scenarios in a virtual space can enhance the accuracy of emergency response plans.

3. Benefits of Implementation

Using digital twins for EHS risk management significantly contributes to preventive maintenance and the fostering of a strong safety culture. The ability to quantify the possibility of an accident in advance makes it easier to provide clear explanations to senior management and provides the basis for investment decisions and strategic equipment upgrades. The results of these simulations can also be used in occupational health and safety committee meetings and training sessions, which helps improve employee safety awareness.

4. Important Considerations for Implementation

On the other hand, the initial investment and the development of a data infrastructure are essential for building a digital twin. In addition to installing sensors and IT infrastructure, ensuring data governance and information security are key challenges. Moreover, close collaboration between on-site staff and the IT department is crucial to create a model that accurately reflects the real working environment.

Conclusion

EHS risk simulation using a digital twin is a next-generation method for enhancing a factory's safety and sustainability. By integrating prediction and countermeasures, companies can simultaneously achieve accident prevention, cost reduction, and increased corporate value. In the future, it is expected that the fusion of digital twins with AI analysis will enable even more advanced risk prediction and automated optimization.