Integrating multiscale data for digital twin-enhanced manufacturing systems: A conceptual and case demonstration

Abstract

This paper explores the integration of data within digital twin-driven multiscale manufacturing systems, examining the core characteristics of data flows in digital twin (DT) environments tailored to manufacturing. In DT frameworks, data are inherently bidirectional, automated, and real-time, which are critical for maintaining the operational integrity of interconnected manufacturing subsystems. Different scales (from machine tool focus to supply chains) and timelines (from operations events to long term planning) make manufacturing system operation complex. This in turn means data integration across these scales and timelines is inherently complex. This study focuses on the dynamics of data flows in DT-driven manufacturing systems that support both forward and backward communication across DT modules and the central DT platform. The overall DT data scheme manages the supervision and cataloging of actions, which includes technical data related to machinery, processes, resources, and rules, alongside performance metrics across various scales and levels over time. A case study of a DT-driven manufacturing unit illustrates the data flow and interdependency in DT data framework. It highlights how data integration across multiple manufacturing stages can improve operational efficiency, fault diagnosis, and resource optimisation. This study lays the groundwork for the implementation of DT in complex, multiscale manufacturing systems by providing an extendible structured framework.