Proactive Approach to Production Control Utilizing Heterogeneous Shop-Level Production Data

This paper presents an approach for integrating data between a production system and its digital twin, focusing on achieving proactivity in production control. Recognizing the unique nature of each production system, this research highlights that a universal, plug-and-play solution is only partially feasible, primarily through general guidelines. The study successfully applied and automated proposed data acquisition methods, resulting in a functional, simulation-based digital twin that adheres to the latest ISO standards. The developed solution incorporates multiple data acquisition strategies, including files containing comma-separated values, a permanent connection to the production control system database, open platform communications unified architecture, and external command files for scenario alteration. The main motivation behind the presented implementation is its application on the shop-floors of small and medium enterprises, where it could provide useful tools for keeping up with the ever-rising competition in the manufacturing sector. This integrated approach allows for affordable and accurate system representation within the proactive simulation concept. The methodology was empirically validated across two distinct production systems: a lab-scale food and beverage line focusing on product tracking, and a sub-assembly line with automated guided vehicle optimization. Despite system variability, the core data acquisition methods demonstrated remarkable adaptability.