When you think of Bell Textron, your mind probably jumps to its high-tech commercial and military aircraft—machines that push boundaries and shape the future of aviation. But there’s so much more happening behind the scenes. Bell isn’t just redefining the skies; they’re also revolutionizing manufacturing. Their secret weapon? Virtual twin technology.
This groundbreaking digital tool is helping Bell operate with precision, speed, and resilience. It’s a collaborative innovation that reduces risks and paves the way for new possibilities in industries where complexity is the norm.
At the heart of these advancements is Bell’s Manufacturing Technology Center (MTC). This hub of ingenuity is where physical and digital worlds combine, giving Bell a space to test, validate, and perfect the technologies that will power tomorrow’s production systems. It’s not just a facility—it’s where ideas come to life.
This article examines how Bell leverages virtual twin technology, providing insightful examples that illustrate its innovative applications, workforce strategies and operational benefits.
Breaking Ground at the Manufacturing Technology Center
The Manufacturing Technology Center serves as Bell’s proving ground for advanced manufacturing processes and innovative technologies. Built with a clear mission, this state-of-the-art facility combines physical and digital realms to deliver tangible results.
A Dual Mandate for Innovation and Validation
Lily English, Bell’s Director of Factory Development and Optimization, emphasizes that the MTC is more than a physical space—it’s a cyber-physical testbed where Bell validates both technologies and processes. “The main mission for the Manufacturing Technology Center is to prove technologies – physically proving technologies and processes, how we’re going to manufacture the product in the future,” she states. This includes:
- Testing and Iteration: Teams evaluate new manufacturing ideas at an accelerated pace. Lily credits the MTC for being a place where “teams can be creative and take ideas and test them” to either refine further or pivot entirely.
- Digital Simulation: Equally vital are the digital capabilities within the MTC, where virtual twin technology plays a role in optimizing factory setups and workflows before physically implementing them. Bell not only tests machinery but conducts full-scale system validations virtually.
The MTC is critical not only for fostering concept innovation but also for ensuring resilience, robustness and real-world impact in manufacturing operations management.
DELMIA’s Role in Bell’s Virtual Twin Success
Bell’s adoption of Dassault Systèmes’ DELMIA has been instrumental in driving their virtual twin initiatives. From designing NC machining processes to simulating entire factory systems, DELMIA offers the precision, flexibility, and predictive analysis that Bell relies on to stay ahead.
Leveraging DELMIA for Enhanced Accuracy and Planning
Lily illustrates how DELMIA supports resilient manufacturing, noting its ability to simulate dynamic environments like fabrication factories, contrasting them with typical assembly lines. “The modeling and simulation software available at the time didn’t fully address our unique requirements [high-mix of parts, different cycle times that have a different sequence of manufacturing]” Lily explains. Bell collaborated with DELMIA developers to adjust the software, enabling them to digitally simulate these complex operations.
This customization bridges a significant gap, providing Bell with a tailored platform that supports:
- Various production methods (e.g., batch processing versus single-piece flow).
- Advanced systems for managing different operational shifts.
- Dynamic problem-solving through scenario simulations.
By validating layouts, workflows, and capital needs in the virtual realm, Bell gains heightened confidence when transitioning to physical execution.
How Virtual Twins Facilitate Agility and Precision
Virtual twin technology offers Bell a robust system for seamless collaboration and predictive validation, enabling engineering, design, and manufacturing teams to work in unison. To quote Mike Bagley, Manager of Manufacturing Innovation, “[We can] make better-informed decisions on how we balance design requirements relative to manufacturing requirements.”
Reducing Time-to-Insight and Costs
Simulation-driven insights significantly reduce the timelines for factory validation. Mike explains, “We are sometimes months ahead of planned releases so we can make earlier engineering decisions.” This proactive approach reduces bottlenecks and aligns manufacturing objectives with engineering outcomes.
Additionally, virtual twin technology improves equipment commissioning. Mike highlights how Bell requests 3D models of new equipment as part of their decision process, stating, “We can define our maximum envelope space for a given piece of equipment and virtually place those given parts inside it. We can then determine an appropriate fit within an allotted space as well as virtual scenarios.”
This advanced preparation minimizes installation issues and ensures alignment with production needs.
Managing Disruptions with Resilience
One of the most critical advantages of virtual twin technology is its ability to prepare factories for unexpected disruptions. According to Lily, “You have to be prepared [for] parts shortages or a power outage [with a] machine down longer than expected. Our ultimate goal is to make a resilient factory, not a perfect one.”
Elevating Human Expertise Alongside Technology
Bell’s modernization extends beyond tools and systems—its workforce also evolves alongside these advancements. Virtual twins bridge generational and technical divides among employees, creating opportunities for enhanced collaboration.
Upskilling Teams with a Blend of Knowledge
Lily describes how Bell’s workforce combines the expertise of experienced veterans with the technological fluency of younger engineers, likening the mix to where “magic happens.” DELMIA supports this strategy by serving as a platform for both process standardization and intuitive interaction.
Notably, the MTC also focuses on growing the skillset of their workforce, which allow operators to learn, test, and deploy new processes safely. “We have a robotics and automation lab – in which the teams not only design and build the lab themselves, but also test different automation in the sectors – growing not only the talent, not only the technology, but the talent to program, create, develop automation,” Lily adds.
Measurable Results from Virtual Twin Adoption
Bell’s integration of DELMIA’s virtual twin functionality has driven measurable benefits across speed, accuracy, and cost metrics:
- Time Savings: Virtually validated processes now reach the production floor months earlier than before.
- Cost Efficiency: Extensive simulations reduce wasted resources and justify capital investments with compelling data points.
- Operational Resilience: Bell optimizes response plans for disruptions, protecting throughput amid unpredictable changes.
- Precision-Driven Manufacturing: Mike underscores the importance of accuracy, noting, “”I think for those that actually use fabrication and NC machining, both accuracy and precision are very important. You should walk away saying, I know that my product is going to be dimensionally correct when I get it to the floor.”
Perhaps most impactful, Bell’s collaborative processes with DELMIA have raised their confidence in meeting both customer expectations and internal benchmarks for quality and affordability.
Inspiring the Future of Manufacturing
The impact of Bell’s approach is clear. Virtual twin technology has saved time, minimized waste, and strengthened operational resilience. Processes that once took months are now ready to roll out in weeks. Equipment installations fit seamlessly and work as planned. And the confidence to meet customer and internal expectations is higher than ever.
But perhaps the most inspiring part of Bell’s story is how their methods set an example for others. They prove that with the right blend of tools, teamwork, and vision, the future of manufacturing isn’t just bright—it’s already here.
Whether you’re running a factory today or dreaming about what’s next, one thing is certain—Bell’s innovations are paving the way for a smarter, more resilient path forward.
Discover what virtual twin technology could do for your business. Start the conversation today and explore how DELMIA’s innovative solutions can help you streamline operations, boost efficiency and stay ahead of the curve. Transform the way you work—get in touch now!