Traditionally, revamping a factory involved costly shutdowns and uncertain outcomes. PepsiCo transformed this approach by employing a precision laser scanner to create a highly accurate 3D digital twin of its manufacturing facility. This virtual model enabled the company to simulate production processes, spot bottlenecks, and experiment with new layouts without disrupting actual operations. Athina Kanioura, PepsiCo’s CEO for Latin America and global chief strategy officer, highlights the goal of optimizing every aspect of the environment—from hardware to human flow—by running millions of simulations to perfect the design. The rise of artificial intelligence has propelled digital twins into powerful tools that mirror and predict real-world manufacturing environments, reducing costly errors and increasing agility. PepsiCo’s pilot programs in the U.S. have already delivered significant gains in production capacity and throughput. A recent partnership with Siemens and Nvidia is allowing the company to scale this technology globally, integrating it into everyday workflows. Beyond driving efficiency, digital twins support PepsiCo’s response to evolving consumer purchasing habits, like smaller, customized online orders, helping the company stay flexible and consumer-focused. Ashin Parikh, senior VP of strategy and transformation, emphasizes the importance of continuously adapting via digital innovation to stay ahead in a rapidly changing industry landscape.
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