A System Dynamics-Based Hybrid Digital Twin Model for Driving Green Manufacturing

Green manufacturing has emerged as a critical objective in the evolution of advanced production systems. Although digital twin technology is widely recognized for enhancing efficiency and promoting sustainability, the majority of existing research focuses exclusively on physical systems. They neglect the impact of soft systems, including human behavior, decision-making, and operational strategies. To address this limitation, the present study introduces an innovative hybrid digital twin model that integrates both physical and soft systems to support green manufacturing initiatives comprehensively. The primary contributions of this work are threefold. First, a novel hybrid architecture is developed by coupling real-time physical data with virtual soft system components that simulate factory operations. Second, lean production principles are systematically incorporated into the soft system, thereby facilitating reduced energy consumption and minimizing environmental impact. Third, a parameter-driven programming model is formulated to correlate critical variables with green performance metrics, and a genetic algorithm is utilized to optimize these variables, ultimately enhancing sustainability outcomes. This integrated approach not only expands the applicability of digital twin technology but also offers a data-driven decision-support tool for the advancement of green manufacturing practices.