TCS Digital Twindex reveals what the manufacturing of the future will look like
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According to the TCS Digital Twindex report, advancements in AI and digital twins will drive the manufacturing of the future, fostering more adaptive and globally competitive companies.
At Hannover Messe 2025, one of the world’s leading industrial technology fairs, held in Germany, Tata Consultancy Services (TCS) presented the “TCS Digital Twindex Report for Future-Ready Manufacturing.”
The report highlights how AI-driven digital twins are transforming industrial production, enhancing the efficiency, adaptability, and resilience of companies in the sector.
The report is based on insights from leaders of technology companies such as Siemens, Schneider Electric, NVIDIA, and JLR, as well as executives from TCS and futurists. It offers an in-depth view on the adoption of digital twins and the growth of AI-driven anticipatory ecosystems, with contributions from industry experts.
With its vast experience in manufacturing and an innovative approach to generative AI and digital twins, TCS is leading the conversation on the evolution of smart and adaptive enterprises.
In this regard, Anupam Singhal, President of Manufacturing at TCS, commented:
“We are on the verge of a new era in manufacturing, driven by digital twins, generative AI, quantum advances, and a deep commitment to safety and sustainability. The ‘TCS Digital Twindex Report for the Future of Manufacturing’ encapsulates our vision of building smart, future-ready, and adaptive enterprises, redefining sector competitiveness, and positively impacting communities worldwide.”
In response to the growing demand for automation and sustainability, the report proposes a strategic plan for manufacturers to thrive in the digital age. It highlights the convergence of technologies such as digital twins, collaborative robots (Cobots), physical AI, and edge computing, which together create smarter, more sustainable, and human-centric manufacturing ecosystems.
The report also identifies the following five key trends in the evolution of the industry:
Industry 4.5 and Beyond – The next phase of manufacturing, where AI, automation, and digital twins combine to create anticipatory and adaptive businesses that not only respond to market changes but anticipate them, improving competitiveness and resilience in production.
Digital Twins as a Real-Time Data Fabric – Digital twins function as the connector of business intelligence, synchronizing real-time data from manufacturing systems to generate predictive insights that improve decision-making and enable greater operational resilience.
AI as the Orchestrator of Intelligence – AI goes beyond specific use cases, evolving to make strategic decisions, run simulations, and optimize the entire manufacturing value chain, thus improving efficiency and reducing costs globally.
Modular and Intelligent Manufacturing – The shift towards decentralized, plug-and-play, AI- and digital twin-powered production models will enable smarter, hyper-localized manufacturing that is highly adaptable at scale, providing unprecedented flexibility to respond to demand changes.
The Human-AI Symphony in Production – In the future of manufacturing, AI will enhance human capabilities, improving decision-making, safety, and collaboration between people and intelligent systems on the factory floor, allowing workers to focus on higher-value tasks.
Rev Lebaredian, Vice President of Omniverse and Simulation Technology at NVIDIA, notes:
“Industrial and physical AI are born in simulation, where they can be tested and validated before being deployed in the real world. By bridging the gap between the digital and physical worlds, large industries are paving the way for software-defined manufacturing and intelligent autonomous systems.”
Digitalization as the First Step.
In a context where automation and AI are essential, experts agree that digitalization is the first step for successfully implementing these technologies. Without digitalization, automation and the use of AI cannot be fully deployed.
Helenio Gilabert, Global Director of Industrial Automation Offer Creation at Schneider Electric, explains:
“If it’s not digitalized, it cannot be automated. If it cannot be automated, intelligence cannot be implemented on it. To fully leverage AI and digital twins, a clear digitalization strategy must first be defined.”
The report also highlights that virtual testing through digital twins is crucial for improving efficiency and reducing errors before they are applied in real production.
Paulina Chmielarz, Director of Digital and Innovation in Industrial Operations at JLR, comments:
“Digital twins are revolutionizing our journey with AI. They allow us to access vast volumes of new data, uncover new categories of information, and open up unprecedented opportunities for innovation and exploration.”
The Central Role of Human Experience.
Although AI will play an increasingly prominent role in data analysis and process optimization, the report emphasizes that human experience must remain central to decision-making. Furthermore, it warns that failing to adopt these technologies could undermine a company’s competitiveness.
Zvi Feuer, Senior Vice President of Digital Manufacturing Software and CEO of Siemens Digital Industries Software in Israel, suggests:
“Imagine a scenario in the next decade where AI agents help us make better decisions… identifying problems before they occur. We’ll be able to solve them, keep production running, and ensure that all logistics reach the right place at the right time. This will be a major shift.”
