PepsiCo is leveraging AI to transform the way factories are designed and updated, focusing on minimizing mistakes and reducing costly changes. The company is utilizing digital twins, virtual models of physical systems, to simulate and adjust manufacturing facilities before implementing changes in the real world.

Digital twins can mimic equipment placement, material flow, and production speed, allowing for the testing of thousands of scenarios that would be impractical or expensive to try on a live production line. By combining digital twins with AI, PepsiCo can identify potential problems earlier and move faster when updates are needed.

The goal of this initiative is to reduce cycle time, enabling teams to validate changes virtually and avoid the lengthy planning cycles and approvals required for physical trials. This approach has the potential to significantly improve supply chain efficiency and product availability.

PepsiCo’s early pilots have shown promising results, with faster validation times and indications of increased throughput. As the company continues to explore the potential of AI-driven digital twins, it may pave the way for a new era of factory design and optimization.