Method for the development and application of digital twins in manufacturing

Abstract Despite the growing interest in digital twins, their practical application in manufacturing remains limited, primarily due to the lack of structured, accessible development methods. This paper introduces a systematic six-step methodology for the development and implementation of digital twins in manufacturing, aimed at bridging the gap between theoretical concepts and practical application. The methodology provides detailed guidance for defining objectives, deriving requirements, implementing functionalities, and validating the digital twin through iterative improvements. The effectiveness of the approach is demonstrated through two use cases: a digital twin for demand response in an aqueous parts cleaning machine, highlighting its potential for energy cost reduction and sustainability, and a digital twin for predictive maintenance of a machine tool spindle, showcasing its role in enhancing operational reliability. This methodology offers a practical framework for expanding the adoption of digital twins in manufacturing. By addressing both technical and practical challenges, it paves the way for broader implementation and standardization. Future research could explore its integration with frameworks such as the Asset Administration Shell and Digital Product Passports to further enhance interoperability and sustainability across manufacturing systems.