HORSE, the Renault-Geely joint venture, is harnessing digital twins at its Valladolid plant to transform powertrain production, boost flexibility in EV output, reduce emissions and embed data-driven decision-making across its operations.
HORSE, the Renault-Geely powertrain powerhouse, has quickly propelled from its recent inception to be at the forefront of digital transformation in automotive production. This impressive rise is largely a consequence of the automaker’s deployment of digital twin technologies and the major enhancements they confer across areas as diverse as process validation, wholesale production efficiencies and sustainability.
As part of HORSE’s strategic move towards a data-centric approach, these digital twins are now reshaping end-to-end manufacturing operations, workforce development, sustainable production initiatives, while determining long-term manufacturing strategies, with the powertrain producer’s Valladolid plant in Spain at the epicentre of the transformation.
”[By leveraging digital twins] allows us to scale production up or down as needed, ensuring that we meet demand fluctuations efficiently, minimising delays and costs”
- Rafael Vázquez, Global Metaverse and Industrial Excellence Director, HORSE
In this exclusive article, HORSE’s Alberto de los Ojos, Valladolid’s Plant Director, shares how the facility’s digital twin deployment has driven automation, predictive analytics, and quality optimisation across machining, assembly, and injection processes, while Rafael Vázquez, Global Metaverse and Industrial Excellence Director, illuminates how digital twins are redefining areas like process planning, real-time monitoring, and adaptive manufacturing in response to fluctuating market demands, particularly in electric vehicle production.
Through the integration of AI and real-time data tracking, HORSE’s Valladolid is proof that digital twins have become an indispensable tool for overall operational efficiencies; and foundational for the future of smart, flexible, and sustainable manufacturing.
Adapting to fluctuating demands through digital twins and the power of data
Automakers are now painfully aware that the transition to EVs and electrification has not been a smooth journey, and that fluctuating demand calls for high levels of flexible production.
With this in mind, the integration of digital twins has significantly enhanced HORSE’s agility as powertrain producers to respond to these fluctuating market demands, particularly in the evolving landscape of electric vehicle (EV) production.
“One of the greatest advantages,” says Vázquez, “is the ability to use real-time data and predictive analytics to anticipate changes in demand. By leveraging digital twins, we can quickly simulate different production scenarios and determine the most efficient way to adjust our operations. This allows us to scale production up or down as needed, ensuring that we meet demand fluctuations efficiently, minimising delays and costs.”
In the context of EV production, digital twins play a vital role in balancing ICE powertrain production with the growing demand for EVs. By simulating various production strategies, HORSE is able to optimise workflows and allocate resources efficiently between different product lines.
”Our digital transformation has been systematically implemented across the factory, with 100% of operational areas involved and a unified framework guiding all projects”
- Alberto de los Ojos, Valladolid Plant Director, HORSE
37 digital twin projects and 100% of operational areas now digitised
Thanks to the deployment of digital twins at Valladolid, HORSE now has greater control over the health of its manufacturing processes and their impact on its powertrains. “This allows us to optimise quality assurance processes to the point where they may eventually become unnecessary,” says de los Ojos. “We apply this approach across our injection, machining, and assembly processes.
“Our digital transformation has been systematically implemented across the factory, with 100% of operational areas involved and a unified framework guiding all projects. To date, we have successfully deployed 37 digital twin projects, further reinforcing our commitment to operational excellence.”
Enhancing process planning and validation within HORSE’s manufacturing operations
Process planning and validation have quickly come to the fore as production efficiencies that have far-reaching ramifications across the entire production ecosystem. Prevention is better than cure, and smart manufacturing principles are at the heart of these processes. Digital twin technology has revolutionised process planning and validation at HORSE by allowing the automaker to create virtual replicas of physical systems, which help optimise production before implementing changes in the real world.
At HORSE, digital twins serve multiple purposes, starting with virtual modelling. By integrating data from sensors and 3D plans provided by suppliers, HORSE is able to construct highly accurate digital representations of physical objects and systems. These models enable it to simulate real-world behaviour with great precision, allowing it to identify potential inefficiencies and refine its processes before any real-world application.
Another crucial aspect is validation and optimisation. “Using digital twins, we can test and refine production processes iteratively, significantly reducing the risk of errors and enhancing the quality of the final product,” says Vázquez. “This approach minimises unnecessary travel and associated costs, as all the teams that will interact with the installation in serial life can collaborate virtually and troubleshoot issues remotely, achieving cost savings of 25% during the COVID year.”
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When it comes to process planning, digital twins allow HORSE to analyse the necessary production steps and optimise resource allocation. “For example,” says Vázquez, “before setting up a new warehouse, we simulate different configurations to determine the ideal number of Automated Guided Vehicles (AGVs) and operators required. This automated approach streamlines decision-making, reducing planning time by almost 35% as well as reducing reliance on manual expertise.”
Read more HORSE Powertrain stories
- Electrification: HORSE launches efficient dual eMotor production
- How HORSE is reimagining smart factories in powertrain production
- Q&A with Patrice Haettel: CEO of powertrain tech firm, HORSE
- Hybrid powertrains – building the bridge to e-mobility
How digital twins facilitate real-time data tracking, automation and sustainability at HORSE’s production facilities
Digital twins are at the heart of real-time data tracking and automation at HORSE’s production facilities. These advanced digital models act as live counterparts to its physical assets and processes, continuously synchronising data from IoT sensors and other sources to provide an accurate representation of ongoing operations. By doing so, they enable precise monitoring of equipment performance, production efficiency, energy consumption and overall system health.
One of the key advantages of digital twins is their ability to automate decision-making. “Through AI-driven analytics,” says Vázquez, “they can autonomously adjust production parameters in response to real-time data, ensuring optimal operations without the need for constant human intervention. This improves efficiency while minimising the risk of human error.
“This technology allows us to control the factory’s lighting and the electrical supply to production equipment. By leveraging real-time production data and external light conditions, we can optimise when lights and compressors are turned on and off. This advancement enhances our operational efficiencies and propels us forward on the path to decarbonisation, making our plant more sustainable.”
“Additionally, HORSE’s digital twin models are regularly updated to incorporate the latest operational data, allowing them to adapt dynamically to changes in production parameters, equipment performance, and environmental factors”
Continuous validation through digital twin and real-world sensor cross-referencing
Ensuring the accuracy and reliability of our digital twin simulations is a top priority at HORSE, as these models serve as the foundation for critical decision-making in our manufacturing processes. “To achieve this,” says Vázquez, “we employ a rigorous validation process that continuously cross-references digital twin data with real-world sensor readings. By doing so, we ensure that our simulations remain precise and reflective of actual production conditions.”
Additionally, HORSE’s digital twin models are regularly updated to incorporate the latest operational data, allowing them to adapt dynamically to changes in production parameters, equipment performance, and environmental factors. Such an approach ensures that they remain relevant and accurate over time.
Developing AI-based resource conservation and waste reduction: digital twins to boost sustainability at Valladolid
De los Ojos emphasises that sustainability is a key pillar of HORSE’s strategy, and this applies across both production and corporate. Its digital twin initiatives reflect this commitment, building on the first digitalisation projects implemented in the factory. “A prime example,” says de los Ojos, “is the AI-based energy management system we are developing, which would provide us with real-time monitoring and control of our primary energy consumption (electricity, gas, etc.).”
This system would allow Valladolid to deliver significant improvements including:
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30% reduction in electricity consumption
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81% reduction in CO2 emissions linked to factory production (thanks to both these initiatives and the use of green electricity)
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48% reduction in energy consumption during non-operational periods
In addition, HORSE’s commitment to data-driven sustainability is further reflected in process optimisation. Leveraging digital twins, HORSE has achieved cost savings in key performance areas:
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5% improvement in overall equipment effectiveness (OEE)
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22% improvement in quality
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35% improvement in energy efficiency
Digital twins tap change in production and people at Valladolid
The introduction of digital twins initially optimised and automated operational processes related to manufacturing, and decision-making, in-step with HORSE’s goal of becoming a wholly data-centric company. And beyond operational efficiencies, the most significant impact has been on its workforce which is undergoing a fundamental transformation as it adapts to the challenges of integrating AI-driven technologies into daily operations.
“This transformation,” says de los Ojos, “is evident across the organisation, where three out of five team members are directly involved in the data-centric transition.
“The initiative has required extensive training, totaling 5,498 training hours, to equip our workforce with the necessary skills to leverage digital tools effectively.”
”The integration of artificial intelligence and machine learning with digital twins will take automation and predictive capabilities to new heights. Future digital twins will not only provide real-time insights but also autonomously learn and optimise themselves, making manufacturing systems more intelligent and self-sufficient”
- Rafael Vázquez, Global Metaverse and Industrial Excellence Director, HORSE
Final thoughts and future focus of production innovation at HORSE
The ongoing evolution of digital twin applications will inevitably continue to influence future operational strategies at Valladolid. De los Ojos says, “we believe that our transformation must be deeply rooted in the use of digital twins. These tools enable us to understand, monitor, manage, and predict the performance of our production system. Ultimately, we envision a future where human operators co-pilot plant operations alongside automated systems.
“Achieving this goal requires continuous investment in tools and technologies that will bring this vision to life. Moreover, we anticipate that the impact of digital twins will extend beyond operations, becoming the foundation of the plant’s strategic direction.”
De los Ojos wraps up, saying, “we firmly believe that the future of our plant depends on the use of data as a strategic asset. To achieve this, we must establish robust data lifecycle management and governance that maximises the potential of our information assets.
“Additionally, the transformation and adaptation of our workforce are crucial to integrating a true data-driven culture. These elements serve as the foundation for a company’s success—both now and in the future.”
Vázquez adds that one of the most exciting aspects of digital twin technology is its potential to reshape not just manufacturing, but the entire industrial ecosystem. “Beyond optimising production, digital twins are increasingly being used for end-to-end supply chain management, from inventory control to supplier coordination, energy consumption, quality predictions, and resource allocations at different moments,” he says.
“Determining the optimal balance of operations across assembly line workstations – based on the number of operators and expected production—has long been a challenge. However, this technology has made it manageable.
”Vallodoid’s ecosystem approach […] includes eleven knowledge centres, five technological partners, four startups, and six clusters/social stakeholders”
“Looking ahead, the integration of artificial intelligence and machine learning with digital twins will take automation and predictive capabilities to new heights. Future digital twins will not only provide real-time insights but also autonomously learn and optimise themselves, making manufacturing systems more intelligent and self-sufficient.
“Digital twin technology is no longer just a concept; it is actively transforming manufacturing operations by improving efficiency, accuracy, and adaptability. At HORSE, we are leveraging digital twins to push the boundaries of what is possible in manufacturing, ensuring we remain competitive in an evolving industry.”
Vallodoid’s ecosystem approach, which includes eleven knowledge centres, five technological partners, four startups, and six clusters/social stakeholders, will boost the likelihood that HORSE continues to rise to the forefront of production innovation
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