TCS Digital Twindex Manufacturing Report

2025 TCS Digital Twindex Series

In 2025, digital twins are evolving from simulation tools into strategic assets. They are enabling businesses to not just respond to change, but to anticipate, adapt, and accelerate in the face of disruption. This report explores how digital twin technology — when fused with GenAI, Physical AI, and agentic AI — is reinventing the very idea of manufacturing.

Featuring perspectives from TCS leaders and clients, this Twindex offers a qualitative roadmap to what comes next: the age of interconnected, human-centered, intelligent industry.

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A new industrial playbook is being written — by intelligence that anticipates, adapts, and accelerates.

Manufacturing is entering Industry 4.5 — bridging automation and intelligence with sustainability and human-machine collaboration.
GenAI enables anticipatory design; Physical AI bridges the virtual-physical divide; agentic AI powers autonomous optimization.
Leading manufacturing companies are shifting from predictive to anticipatory manufacturing models.

Digital twins have evolved into the real-time data fabric powering enterprise-wide decisions.
They enable simulation, synthetic data generation, and predictive insights across operations.
TCS helped a global auto OEM improve efficiency using integrated digital twin observability.

AI connects and activates insights from digital twins to drive real-time action.
Use cases include predictive maintenance, workflow redesign, and factory-floor intelligence.
GenAI adds reasoning; agentic AI drives autonomous learning and adaptation.

Manufacturing is shifting toward modular and flexible models, supported by AI-powered micro-factories in some segments.
These hubs leverage digital twins, GenAI, and Physical AI for responsive, localized production.
They offer CapEx flexibility, real-time agility, and hyper-customization capabilities.

The factory of the future keeps humans in the loop — empowered, not replaced.
Digital twins and agentic systems enable scenario planning and decision augmentation.
Jaguar TCS Racing exemplifies the AI-human partnership in high-performance environments.

Future-ready Factories

The factory of the future is designed not just for efficiency — but for human empowerment, safety, and resilience.

Key shifts include:

From automation to augmentation: AI supports decision-making, not just execution
From interfaces to interaction: Conversational AI lowers the barrier to intelligence
From training to trust: AI builds confidence by learning from human feedback

As manufacturing enters this new phase, people will not be displaced by AI — they will be amplified by it.

Conclusion: The Sentient Enterprise is Already Here

The future of manufacturing is not in the machines, but in the intelligent networks they create.

What began as a technological ambition is now a business necessity. Digital twins — combined with GenAI, agentic AI, and Physical AI — have moved beyond experimentation. They are reshaping how factories function, how people work, and how decisions are made across the industrial value chain.

The shift from reactive to anticipatory, from centralization to intelligent decentralization, and from automation to augmentation is not a future scenario. It is unfolding now.

Anupam Singhal

President – Manufacturing, TCS

We stand at the threshold of a new manufacturing era, driven by digital twins, generative AI, quantum-powered advancements, and a deep commitment to everything from safety to sustainability. The 2025 Digital Twindex Report encapsulates our vision for building intelligent, future-ready, and adaptive enterprises—redefining industry competitiveness and enriching the lives of citizens and communities around the globe.

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About Us

Discover why customers choose TCS

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Recent recognitions

Want to be a global change-maker? Join our team.

Find the latest news about TCS

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TCS Digital Twindex Report: Manufacturing

2025 TCS Digital Twindex Series

A new industrial playbook is being written — by intelligence that anticipates, adapts, and accelerates.

Into Industry 4.5 and Beyond

Digital Twins as the Data Backbone

AI as an Orchestrator of Intelligence

Modular and Intelligent Manufacturing

The Human-AI Symphony in Manufacturing

Future-ready Factories

Conclusion: The Sentient Enterprise is Already Here

Anupam Singhal

Perpetually Adaptive Enterprise

About Us

Discover why customers choose TCS

Upcoming events

Recent recognitions

Want to be a global change-maker? Join our team.

Find the latest news about TCS

Recent News

2025 TCS Digital Twindex Series

A new industrial playbook is being written — by intelligence that anticipates, adapts, and accelerates.

Into Industry 4.5 and Beyond

Digital Twins as the Data Backbone

AI as an Orchestrator of Intelligence

Modular and Intelligent Manufacturing

The Human-AI Symphony in Manufacturing

Future-ready Factories

Conclusion: The Sentient Enterprise is Already Here

Anupam Singhal

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