Development of Digital Twin in an Assembly Production System: Case Study

With the advancement of manufacturing technology, production systems have become increasingly complex. Digital twin has gained attention in these complex systems for enhancing productivity and optimizing operations. This paper proposes a method for developing a digital twin capable of predicting future abnormal situations in assembly production systems. Real-time synchronization between the actual manufacturing system and its digital twin enables the implementation of a virtual factory. This virtual factory can accurately represent the real-time status of the target system using state calculation logic. Based on the real-time monitoring information provided by the virtual factory, it is possible to set the initial condition of simulation. When the digital twin predicts production issues, it provides the manufacturing operators with this prediction information. The operators then use this information to identify the cause and take proactive actions. Finally, this paper presents a case study where the proposed digital twin development method has been applied to a domestic home appliances assembly line.