Wistron Uses NVIDIA Omniverse and NVIDIA Modulus to Build Digital Twin Platform, Transforming Factory Planning and Operations


(TAIPEI, TAIWAN) 19 March 2024– Wistron has utilized the NVIDIA’s Omniverse software development platform and the NVIDIA Modulus framework to create a proprietary application platform, dubbed the "Wistron Foundation APP." We have incorporated technologies such as OpenUSD, NVIDIA CloudXR and physical deep-learning to develop digital twin applications. The application platform not only accelerates the digital transformation of industries but also enhances the ability to forecast future production scenarios.

Confronted by the recent surge in AI applications, Wistron has been tasked with the challenge of supplying an increased quantity of NVIDIA DGX systems to end customers. Expanding production capabilities—both by optimizing current production flows and establishing new manufacturing sites—is critical for swift and efficient resolution. In this context, the Omniverse development platform is helping Wistron explore the potential of digital twins for planning and operations, allowing us to strategize our expansion plans effectively. 


Establishing a new factory through NVIDIA Omniverse and CloudXR technology

Harnessing the potentials of the Omniverse development platform, Wistron has built a dynamic and streamlined simulation platform that elevates all facets of the manufacturing procedure. Embedding NVIDIA Omniverse and CloudXR technology into the Wistron platform enables engineer to leverage robust server capabilities from a distance, facilitating a remote immersive preview of the upcoming factory.


When Wistron established a new factory, it saved 2 months of time through this technology. This primarily centers around the early stages of layout planning and making adjustments during the construction phase.


Constructing simulations and digital dashboards with NVIDIA Omniverse, facilitating efficient production processes and effectiveness

Picture yourself in various settings—be it at the office, home, or in the field—yet still maintaining the ability to immerse yourself in the intricacies of the factory floor. Free your manufacturing horizons from the constraints of geography.


The virtual dashboard in the Wistron platform, is generated in real-time using OpenUSD technology, and showcases the production status of individual workstations, represented by regional colors.


Events of an issue affecting the production pace at a particular location are distinctly highlighted on the virtual dashboard. This empowers managers to swiftly allocate resources for resolving the problem.


Simultaneously, the IoT, production data, test logs, and more from each machine can undergo analysis through Power BI’s chart analysis function. 


By evaluating the performance of multiple machines of identical models, the dashboard identifies areas exhibiting subpar performance and scrutinizes them to determine the root causes. This ensures the consistent operation of the machines and facilitates early warning analysis for future maintenance.


Simulating future performance

Concerning forecast (FCST) simulations, our objective is to utilize real historical data to uncover current issues and simulate future optimal solutions within a risk-free virtual environment.


Initially, Wistron engineers gather production data via the IoT, then meticulously clean and analyze it. Subsequently, they input this data (including input quantity, cycle time, output, etc.) into the scenario model of simulation software for simulation.


Simultaneously, the simulation results can be visualized in the Omniverse powered Wistron platform. Based on these outcomes, planners can scrutinize potential issues, such as bottleneck stations and logistical conflicts. Wistron engineers can then iterate the FCST simulation process following optimization. Once bottleneck stations are identified, additional resources can be invested to enhance their performance.


Finally, the Wistron platform facilitates a re-layout design to help optimize output as orders evolve. Leveraging Omniverse simulation technology, Wistron achieved a noteworthy 51% enhancement in the factory's bottleneck production line efficiency.


Energy efficiency in high-performance test room

Amidst the ESG wave, energy conservation emerges as the pivotal factor in production. To enhance the energy efficiency and productivity of the high-performance test room dedicated to testing supercomputing facilities, a digital twin was created utilizing NVIDIA Omniverse.


For factories equipped with thousands of physical sensors, the digital twin can furnish real-time data on the core temperature, inlet temperature of supercomputing facilities, and the return temperature of air conditioning systems.


By seamlessly connecting with the IoT Hub and the BMS server, engineers can monitor various aspects of each supercomputing facility, including the testing stage, duration, and outcomes.


Integrated with NVIDIA Modulus, an AI computational fluid dynamics (CFD) model was trained to expedite the airflow and thermal simulation.


By integrating the temperature prediction model with the AI-CFD model, it becomes possible to swiftly pinpoint hotspots within the room for the upcoming 30 minutes. This allows for effective control of the risk of overheating in each supercomputing facility within the space.


Ultimately, the recommendation system was devised to aid in identifying the optimal testing location for the new supercomputing baseboard.


By integrating the digital twin of the testing facility with IoT technologies, we've achieved an energy efficiency improvement of up to 10%.


Using Omniverse to develop the Wistron Foundation APP

The Wistron Foundation APP was constructed utilizing Omniverse.  In cases where multiple factories require the establishment of a virtual replica of a plant, there is no necessity to initiate the process from the beginning. Instead, engineers can efficiently commence by directly utilizing the models and service extensions built already in the Wistron Foundation APP library. By aligning it with the designated layout, feeding IoT and operation data and importing extensions, the creation of a virtual factory for that plant can be rapidly accomplished.


This enhancement will substantially elevate Wistron's digital transformation prowess, particularly for enterprises operating numerous facilities across various nations. Each distinct application is crafted for a specific objective and requires only minor modifications to align with real-world conditions.


During the refinement of the existing production workflow and the construction of a new factory, Wistron has extensively leveraged Omniverse technology, delving deeply into its potential applications. Moving forward, we plan to employ the Wistron Foundational APP for swift development of pertinent applications, utilize CloudXR for remote collaboration and assistance, and develop and simulate new product manufacturing processes. This strategy is aimed at taking advantage of Omniverse developer capabilities and helping advance the digitalization of the industry.