Digital Twin in manufacturing: A categorical literature review and classification

“(Tao et al. 2017; Lee et al. 2013a; Rosen et al. 2015) To get a more common understanding of the Digital Twin, the level of integration are discussed in the following section.”

“(Kuhn 2017; Boschert, Rosen 2016; Rosen et al. 2015) In terms of manufacturing, (Garetti et al. 2012) has the following definition for a Digital Twin: “The DT consists of a virtual representation of a production system that is able to run on different simulation disciplines that is characterized by…”

“While some researchers, especially coming from the class Digital Shadow, see a further research need in developing the optimization and simulation methods, others see the data connectivity as main problem.(Yang et al. 2016; Um et al. 2017b; Vachálek et al. 2017; Schleich et al. 2017; Frazzon et al. 2016; Kuhn 2017; St…”

“…stages of machine life cycle to handle data/information more efficiently and further achieve better transparency of a machine’s health condition (Lee et al. 2013b) Layout planning (Uhlemann et al. 2017a) o continuous production system evaluation and planning o Automatic and application…”

“Categorical literature review Reference Type Level of integration Focused area Technology Boschert, Rosen (2016) review DT product lifecycle simulation Bottani et al. (2017) case-study DT PPC simulation Brenner, Hummel (2017) definition DT PPC sensors Cai et al. (2017) concept DM maintenance simulation Frazzon et al.…”

“While some researchers, especially coming from the class Digital Shadow, see a further research need in developing the optimization and simulation methods, others see the data connectivity as main problem.(Yang et al. 2016; Um et al. 2017b; Vachálek et al. 2017; Schleich et al. 2017; Frazzon et al. 2016; Kuhn 2017; St…”

“…al. (2017b) concept undefined PPC AutomationML, XML, CPS, PLC, OPC-UA, MQTT, MTConnect Vachálek et al. (2017) case-study DS PPC Plant Simulation, OPC-UA Weyer et al. (2016) concept DS PPC simulation, CPS, SOA Yang et al. (2016) concept DS PPC simulation, optimization Zhang et al. (2017) concept…”

“While some researchers, especially coming from the class Digital Shadow, see a further research need in developing the optimization and simulation methods, others see the data connectivity as main problem.(Yang et al. 2016; Um et al. 2017b; Vachálek et al. 2017; Schleich et al. 2017; Frazzon et al. 2016; Kuhn 2017; St…”

“In terms of manufacturing, (Garetti et al. 2012) has the following definition for a Digital Twin: “The DT consists of a virtual representation of a production system that is able to run on different simulation disciplines that is characterized by the synchronization between the virtual and real system, thanks to sense…”

“…o Improved decision support by means of detailed diagnosis o Automatic planning and execution from orders by the production units Maintenance (D’Addona et al. 2017; Susto et al. 2015) o Identify the impact of state changes on upstream and downstream processes of a production system o…”

“…stages of machine life cycle to handle data/information more efficiently and further achieve better transparency of a machine’s health condition (Lee et al. 2013b) Layout planning (Uhlemann et al. 2017a) o continuous production system evaluation and planning o Automatic and application…”

“…TCP/IP, optimization Jain et al. (2001) concept DS layout planning simulation Kaylani, Atieh (2016) case-study DM PPC discrete event simulation Kuhlenkötter et al. (2017) concept DM product lifecycle - Kuhn (2017) review DT maintenance simulation Kumar et al. (2015) case-study DM PPC…”

“…al. (2017) review DS product lifecycle simulation Tao et al. (2017) concept DM PPC Semantic Web Terkaj, Urgo (2015) concept undefined PPC simulation, CPS Terkaj et al. (2015) concept DM process design simulation, Semantic Web, UML Theuer, Lass (2016) concept undefined PPC simulation, CPS, System…”

“(Weyer et al. 2016; Um et al. 2017b; Uhlemann et al. 2017a; Lindström et al. 2017; Kuhn 2017) 4.”

“…study DM product lifecycle discrete event simulation, sensors Gyulai et al. (2016) concept DM layout planning Plant Simulation, TCP/IP, optimization Jain et al. (2001) concept DS layout planning simulation Kaylani, Atieh (2016) case-study DM PPC discrete event simulation Kuhlenkötter et al.…”

“While some researchers, especially coming from the class Digital Shadow, see a further research need in developing the optimization and simulation methods, others see the data connectivity as main problem.(Yang et al. 2016; Um et al. 2017b; Vachálek et al. 2017; Schleich et al. 2017; Frazzon et al. 2016; Kuhn 2017; St…”

“…DS maintenance PHM, TCM, sensors Lindström et al. (2017) case-study DS maintenance PHM, sensors Mell, Grance (2011) case-study DS PPC visualization Müller et al. (2017) review DT manufacturing in general - Pawlaszczyk (2006) review DT manufacturing in general optimization Prager, David (2016)…”

“Categorical literature review Reference Type Level of integration Focused area Technology Boschert, Rosen (2016) review DT product lifecycle simulation Bottani et al. (2017) case-study DT PPC simulation Brenner, Hummel (2017) definition DT PPC sensors Cai et al. (2017) concept DM maintenance simulation Frazzon et al.…”

“…RFID Friedrich et al. (2014) concept DS maintenance - GE Power Digital Solutions (2016) study DM product lifecycle discrete event simulation, sensors Gyulai et al. (2016) concept DM layout planning Plant Simulation, TCP/IP, optimization Jain et al. (2001) concept DS layout planning…”

“Categorical literature review Reference Type Level of integration Focused area Technology Boschert, Rosen (2016) review DT product lifecycle simulation Bottani et al. (2017) case-study DT PPC simulation Brenner, Hummel (2017) definition DT PPC sensors Cai et al. (2017) concept DM maintenance simulation Frazzon et al.…”

“Categorical literature review Reference Type Level of integration Focused area Technology Boschert, Rosen (2016) review DT product lifecycle simulation Bottani et al. (2017) case-study DT PPC simulation Brenner, Hummel (2017) definition DT PPC sensors Cai et al. (2017) concept DM maintenance simulation Frazzon et al.…”

“(Zhang et al. 2017; Salleh et al. 2017) There is a tremendous benefit of the Digital Twin for applications in industry, but there is still a lack of case-studies which apply the concepts in practice.”

“(Weyer et al. 2016; Um et al. 2017b; Uhlemann et al. 2017a; Lindström et al. 2017; Kuhn 2017) 4.”

“…case-study DM PPC discrete event simulation Kuhlenkötter et al. (2017) concept DM product lifecycle - Kuhn (2017) review DT maintenance simulation Kumar et al. (2015) case-study DM PPC optimization Lee et al. (2013b) concept DS maintenance PHM, CPS Lee et al. (2013c) concept DS maintenance…”

“[11] to produce a categorical review table of selected publications.”

“5 Fidelity [33] [80] [108] [24] [85] [8] [56] [88] [68] [112] [99] [78] [32] [111] [36] [7] [71] [63] [61] [73] [20] [67] [6] [4] [48] [55] [95] [16] [92] [98] [87] [9] [66] [110] [18] [89] [12]”

“, from 2001 to 2006 [41], from 2014 [37], from 2005 to 2016 [38]).”

“(Stark et al., 2017) characterizes the DT as (1) an unique instance of the universal Digital Master model of an asset, (2) its individual Digital Shadow and (3) an intelligent linkage (algorithm, simulation model, correlation, etc.) of the two elements above (Kritzinger et al., 2018).”

“This effort covers different stages in the production and also different applications cases [27].”

“Basically, this implies that they must have a feedback loop in which a norm, sensor, discriminator, decision maker, and effector are present (de Leeuw, 1997; Int Veld, 2002).”

“Although there is no commonly agreed conceptualization or definition of the term (Kritzinger et al., 2018; Gerber et al., 2019), numerous organizations have defined digital twins in terms of their functions and characteristics.”

“Some works focus on specific domains, such as manufacturing [54], aerospace [60] and production science [39], others are general [20, 73].”

“…will be some confusion in the coming years about what a DT is and when a technology can be considered a DT. Research has been done to classify technologies based on how close they are to becoming DT (Kritzinger et al., 2018), but it is still difficult to identify when a system can be called a DT.”

“Meanwhile, the authors in [6] reviewed digital twins for Industry 4.”

“…of the Digital Twin originated from the aerospace field (Shafto et al. 2010), and then expanded to industrial manufacturing (Negri et al. 2017, Kritzinger et al. 2018, Zhuang et al. 2018, Tchana et al. 2019, Zhang et al. 2019), has attracted increasing attention in the built environment…”

“However, distinguishing digital twins from other types of models is crucial to realize the applicability of utilizing the completely mirrored digital twin for city-scale modeling; that is, the level of data integration, which varies according to the type of model, between the two counterparts (digital and physical) of…”

“, BIM) and DT as similar concepts or used them interchangeably [33,66,67].”

“…there are many research activities for realizing CPS and mono-directional information flow from the physical object to the digital model (digital shadow), and in a further step a bidirectional information flow between both models to control the physical system through a so-called digital twin [66].”

“In an ideal world, the digital component would have all the system’s information that could be acquired from its physical counterpart (Kritzinger et al. 2018).”

“A DT can help in (i) production planning and control by planning and executing the orders automatically and improving decision support by means of a detailed diagnosis, (ii) maintenance by evaluating and analyzing machine conditions, identifying any changes in the production system and its effects, and taking anticipa…”

“In [9] several definitions ofDigital Twins are compared and evaluated.”

“of the literature review presented in this article, however, is limited to the O&G industry and follows a similar approach to that presented in [11], [38]–[42].”

“To further clarify such differences and highlight the characteristics of a DT, Kritsinger et al. identify in [2] three variants of mirroring systems, classifying them as: digital model , an isolated system without automatic connection to the real world; digital shadow , a system with an automated…”

“The interview participants viewed digital twins as a twoway interaction between a virtual model and physical asset, which has been highlighted by several authors [12,30].”

“Moreover, digital twin technologies may be the driving technologies to improve resource reconfigura-tion [172]–[174].”

“…limited to construction (Opoku et al., 2021), healthcare (Semeraro et al., 2021), industrial production (Negri et al., 2017; Rasheed et al., 2020; Kritzinger et al., 2018), aviation (Mandolla et al., 2019) and automotive (Alcácer and Cruz-Machado, 2019) industries, meteorology, education and…”

“Kritzinger et al. (2018) distinguishes between the various digital forms and categorized them as digital model, digital shadow and digital twin.”

“…ones in industry currently, including the employment of a digital model where the digital representation of a physical system exists without automated data communications in both ways, and a digital shadow where model exists with one-way data transfer from physical to virtual component [2].”

“flow, from physical entity to the virtual side, whilstnot realising the close-loop of data which involvesusing virtual data to affect the physical entity [29].”

“physical product can be obtained from its DT [24]–[26].”

“…Extensible Markup Language (XML), Kepware, ZigBee, Message Queuing Telemetry Trans-port (MQTT), MySQL, Application Programming Interface (API), UML/SD, MTComm, Standard Internet Protocol, Industrial Internet of Things (IIoT) Protocol, Wireless Communication, TCP/IP Connection [111,112].”

“This enables the digitally extracted simulation model to be a high-fidelity replica of the real entity that it is modeling in real-time (Kritzinger et al., 2018), (Tao et al., 2019).”

“…years, more authors are inclined to the notion that the vision refers to a comprehensive virtual representation with connectivity to the physical and functional description of the product/system throughout the lifecycle phases (Yun, Park, and Kim 2017; Cheng et al. 2018; Kritzinger et al. 2018).”

“The three concepts implement different levels of integration between the physical and digital entities [17]: a digital model does not implement any form of automated data exchange between the physical and the digital entities (i.e., in Figure 2, the “Data stream” and “Actions” connections are…”

“The other two axes are the “ Value Life-cycle ” , a proposed agile iterative/incremental approach to development lifecycle (Aheleroff et al., 2019), and data flow based on a digital twin integration hierarchy (Kritzinger et al., 2018).”

“For instance, Barricelli et al. (2019) argue that a digital twin is more than a simple model and simulation and refers to the works of Grieves (2014), Kritzinger et al. (2018), Negri et al. (2017) and Boschert and Rosen (2016).”

“Digital twins are understood as one of the key enablers of digital transformation in the manufacturing industry [23,31,33,34].”

“However, some applied case studies already exist in the literature [17].”

“Utilizing the levels of data integration of Kritzinger et al. (2018) for digital twins in manufacturing, as shown in Fig.”

“A survey shows more than half of declared DT research papers about manufacture only reached the digital shadow level of integration [13].”

“approach that simplifies envelopment is to strive for “gray-box models,” as exemplified by the creation of “digital twins” that can simulate real, physical processes (see El Saddik, 2018; Kritzinger et al., 2018).”

“Due to the real-time interconnectivity, each decision made by the twin grid flows into the physical layer with the help of incident response strategies [91].”

“[85] Kritzinger W, Karner M, Traar G, Henjes J, Sihn W, Kritzinger W, et al.”

“Digital Model (left), igital Shado ( i dl ), i it l in (right) [21].”

“As the authors of [37,52,69] provided more extensive surveys on recent developments in the area of digital twins for manufacturing, we proceed with highlighting key enabling technologies for modeling digital twins, as presented recently by Rasheed et al.”

“According to Kritzinger et al. (2018), DT has experienced three evolutions in its development (Figure 1): the digital model does not have an automated data exchange between physical and digital objects; the digital shadow has an automated unidirectional data flow between physical and digital…”

“Providing a less complex definition, Lee and Seshia (2011) described CPS as a tight integration of computational resources with physical processes.”

“Consequently, Kritzinger et al. (2018) proposed a classification of the digital-twin concept based on how the data exchange between the virtual replica and its physical counterpart is realized.”

“Kritzinger et al. (2018), Negri, Fumagalli, and Macchi (2017), Melesse, Di Pasquale, and Riemma (2020), Psarommatis and May (2022) and Singh et al. (2020) focus on manufacturing-oriented digital twins.”

“According to the literature review performed by [15] one of the most common technologies found in the literature for model construction is discrete event modelling.”

“The following list of problems that are likely to be faced while attempting to introduce a Digital Twins has been established based on the concerns posed by [17,96,97].”

“There are bi-directional data connections between the physical product and its virtual twin; however, the data is exchanged manually [27,28], meaning the virtual twin represents a certain status of the physical product with the manually controlled process of synthesis.”

“Furthermore, the data flows are fully integrated for both directions, one may refer to Digital Twin where the digital objects generate feedback for the control of the physical object (Kritzinger et al. 2018).”

“Kritzinger et al. (2018) explained more on PLM, which referred to an industry presentation describing DT as a digital informational construct of a physical system created as an entity on its own but linked to the physical system.”