Maintenance 4.0: technology trends towards the digital twin for operation and maintenance

Gemelos digitales operación y mantenimiento


27 May 2021


On-line - via Zoom


9:30 am - 11:00 am



The Industry 4.0 defines a set of interconnected assets and systems spanning the entire value chain. The conjunction of different enabling technologies, under the concept of Digital Twin for Operation and Maintenance, as a platform for hybridising operational data, physical failure models and production and maintenance information, provides a great example of how to improve and optimise the maintenance and availability of complex assets throughout their entire lifecycle. These can be applied in areas such as advanced manufacturing, energy transition and sustainable construction and mobility.

There is a growing awareness of the benefits and added value that optimal maintenance brings to business processes. Changes in maintenance paradigms, with a shift towards predictive or prescriptive models, are opening doors to increasing equipment availability and reducing maintenance costs.

This development is accompanied by the integration into maintenance solutions of enabling technologies such as IoT or artificial intelligence, which are changing the landscape of industrial equipment monitoring: they are making it possible to develop diagnostic and predictive services to assess the state of health of industrial equipment.

The concept of Digital Twin Digital Twin for Operation and Maintenance, as a digital replica of components, subsystems and complete systems, is proposed as a platform for hybridising failure data, and information on maintenance, context, operation and business requirements. It generates decision-making support systems taking all of these dimensions into account, and helps companies to make the best decisions by reconciling maintenance investment with production requirements.

This approach makes it easier for companies to improve the design of equipment by making it more reliable and maintainable. It also makes it possible to develop predictive and prescriptive maintenance to determine the current and future state of assets in different conditions of use, avoid undesired shutdowns and increase availability, while reducing maintenance costs and ensuring the required quality parameters.

Consequently, better designed and better maintained equipment will be more efficient, with lower consumption and emissions and an extended service life, and will be aligned with the principles of the circular economy; promoting the efficiency of systems and optimising the use of resources.


  • CEOs
  • CTOs
  • Maintenance managers
  • Heads of production
  • Anyone interested in learning more about the possibilities of new technologies such as AI in maintenance


  • Maintenance: concept and its levers for adding value to the business
  • New maintenance strategies
  • Enabling technologies for maintenance 4.0
  • Artificial intelligence and digital twin for operation and maintenance


  • Jokin Rubio Botía is Head of the Reliability and Maintenance Team at TECNALIA. He began his research work in 2003 focused on applied research in the field of industrial safety and, since then, he has undertaken and led R&D projects nationally and in Europe, also taken part in various forums such as Technology Platforms and ERANETs. Since 2011, his work has focused on maintenance, with a particular emphasis on the industrial sector, and he currently heads the Reliability and Maintenance Team at TECNALIA. He works on developing new tools and technologies in the field of operation and maintenance under the umbrella of the Industry 4.0 concept.

Further information


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