Digital twins (DT) are revolutionising the manufacturing space by enhancing data accessibility and physical asset tracking. This technology facilitates the integration of data from diverse sources, providing a holistic view of production processes. The research identifies following key functionalities in applying DT in manufacturing.

The manufacturing environment Tracking and Locating the parts is the key. Products released to the production line are tagged with RFID, enabling real-time location tracking within the physical factory. This information is then mirrored in the digital twin, creating a synchronized representation. Scanning at each stage confirms location and triggers access to relevant information like Bill of Materials (BOM) and standard work procedures for that stage.

The digital twin connects with DC WIFI tooling, setting precise torque, angle, and quantity requirements for fastening steps. This creates an automated Poka-Yoke system, preventing operators from progressing until all fastenings meet the pass/fail criteria set by the digital twin, ensuring quality control.

The digital twin aggregates data from various sources, offering insights into key metrics like cycle time, Takt time, Overall Equipment Effectiveness (OEE), line stops, quality issues, and production volumes. This helps with key aim of comprehensive data analytics and reporting in manufacturing. This data is displayed in customisable dashboards and reports, providing a clear overview of all production lines and departments.

By visualizing the physical factory in a user-friendly format, the digital twin enables intuitive prediction of production line requirements and outputs. This empowers informed decision-making regarding production scheduling, line balancing, and lead-time communication with customers.

In essence, digital twins in manufacturing offer a powerful combination of real-time tracking, automated quality control, and comprehensive data analysis. In Manufacturing and Materials Processing, this facilitates informed decision-making, optimizing production processes for efficiency, quality, and customer satisfaction.