Enhancing Manufacturing Excellence with Digital-Twin-Enabled Operational Monitoring and Intelligent Scheduling

Abstract

This research examines the potential of digital twin (DT) technology for reformation within China’s traditional solid-wood-panel processing industry, which currently suffers from production inefficiencies and the slow adoption of digital technology. The research centers around developing a digital twin system, elucidating improvements in manufacturing efficiency, waste management, process simulation, and real-time monitoring. These capabilities facilitate immediate problem solving and offer transparency in the process. The digital twin system is comprised of physical, transport, virtual, and application layers, employing a MySQL database and using the Open Platform Communications Unified Architecture (OPC UA) protocol for communication. The application of this system has led to heightened production efficiency and better material use in the solid-wood-panel manufacturing line. Integrating the dynamic selection adaptive genetic algorithm (DSAGA) into the virtual layer drives the system’s efficiency forward. This evolved approach has allowed for an enhancement of 8.93% in the scheduling efficiency of DSAGA compared to traditional genetic algorithms (GAs), thereby contributing to increased system productivity. Real-time mapping and an advanced simulation interface have strengthened the system’s monitoring aspect. These additions enrich data visualization, leading to better comprehension and a holistic process view. This research has ignited improvements in solid-wood-panel production, illustrating the tangible benefits and representing progress in incorporating digital technology into traditional industries. This research sets a path for transforming these industries into smart manufacturing by effectively bridging the gap between physical production and digital monitoring. Furthermore, the adjustability of this approach extends beyond solid-wood-panel production, indicating the capability to expedite movement towards intelligent production in various other manufacturing sectors.