5-Dimensional Definition for a Manufacturing Digital Twin

Abstract

The Digital Twin is a recently developed innovative technology in Industry 4.0. The cyber-physical system (CPS) is a concept closely connected with Industry 4.0 that can form a basis for creating a Digital Twin. In this paper, a comprehensive model of a Digital Twin approach for a manufacturing environment and related production processes is proposed. The presented model is based on combining a 5-Dimensional definition for the Digital Twin and cloud-based CPS (C2PS) architecture. The model consists of five layers to replicate the physical object as a virtual object and to collect and convert data. Analysis of the virtual model for prediction of future development, decision-making, re-configuration, what-if analysis, and understanding of the effect of changes in the real time process is performed in the fourth layer. The user interface layer is the connection between the virtual and physical model. Use of a Digital Twin in manufacturing enables improvement in the effectiveness of Lean Manufacturing, leading to savings in resources such as cost and time. Uncertainties inherent in manufacturing processes mean that the Digital Twin approach is a more suitable method for optimization of the overall process and the sub-processes than pure simulation. An accurate Digital Twin model can improve safety, save costs, speed up manufacturing of new products and implementation of new processes, and provide global optimization results. In practice, however, provision of data is a challenge to use of the Digital Twin approach because modern manufacturing uses a variety of data in different formats with different owners. Access to all required data and information and obtaining permission for its use in creation of a Digital Twin is a topic for future research.