Towards Holistic Cyber-Physical Production Systems in Existing Production Environment: Challenges from a Case Study

Cyber-physical production systems (CPPS) are the backbone of Smart Production. Digital transformation often starts from a hierarchical systems landscape based on the automation pyramid with legacy systems and low data availability. CPPS’s are characterized by a decentralized structure with the ability to share data and services across the value chain, to gain benefits in line with Industry 5.0 demands. Literature proposes different models, which in theory should enable companies with individual starting points and legacy systems to implement a holistic CPPS architecture. Nevertheless, companies struggle with its implementation. Therefore, the purpose of this article is to analyze challenges when implementing a holistic CPPS architecture. A case study assesses the transformation of a global manufacturing company towards a holistic CPPS architecture with input from stakeholders at management level to operators. This paper provides examples and insights into current challenges and gives recommendations for next steps towards a holistic CPPS architecture.