Digital Twin-Based Integrated Assessment of Flexible and Reconfigurable Automotive Part Production Lines

The manufacturing industry has witnessed rapid changes, including unpredictable product demand, diverse customer requirements, and increased pressure to launch new products. To deal with such changes, the reconfigurable manufacturing system has been proposed as one of the advanced manufacturing systems that is close to the realisation of smart manufacturing since it is able to reconfigure its hardware, software, and system structures in a much quicker manner. Conventional simulation technologies lack convergence with physical manufacturing systems, and reconfigurable manufacturing lines require the manual construction of production line models for each reconfiguration. This study presents a digital twin-based integrated reconfiguration assessment application that synchronises with real-time manufacturing data and provides accurate, automated simulation functionality to build and analyse a manufacturing system. The paper discusses the architectural design and implementation of the application, an information model, and an assessment model that enable quantitatively assessment on reconfigurations of manufacturing systems from various aspects. The effectiveness of the proposed application is verified via application to an automotive parts production line to assess the reconfiguration indicators of the manufacturing system under different scenarios. The results reveal that the proposed application provides faster and more accurate reconfiguration assessments compared to existing methods. The findings of this study are expected to facilitate accurate and consistent decision making for evaluating the various indicators of production line performance.