Abstract: A method of developing a product is provided that includes generating a digital system model (DSM) that describes the product and a manufacturing process for the product, and generating a digital twin (DTw) of an instance of a component of the manufacturing process, the DTw including a digital replica of the instance. The method includes receiving attribute data for attributes of process/process characteristics subject to sources of variation that affect product quality. The digital replica is executed with input of the attribute data, and thereby updating the DTw to replicate the instance of the component of the manufacturing process as performed. A data analysis of the manufacturing process is performed based on the DTw as updated, and the manufacturing process is modified based on the data analysis to reduce variability in one or more product characteristics. The DTws of multiple instances may be used to generate further improvement.