Hierarchical Blockchain for Mapping Manufacturing Process Flow

As manufacturing processes become increasingly complex, maintaining quality and improving efficiency requires mapping of process flows. Mapping process flows, in turn, depends on comprehensive end-to-end data traceability. Such traceability relies on lifecycle data that capture every stage, from raw-material handling to final-product assembly, and provide indispensable insights for process refinement. However, conventional centralized database-based systems for managing these data introduce single points of failure and remain vulnerable to tampering and cyberattacks. As a result, data traceability and authenticity are compromised. Therefore, this research develops a novel blockchain architecture coupled with digital twin (DT) model to secure end-to-end documentation of manufacturing process flows. First, a hierarchical blockchain framework is developed to record production events and ensure comprehensive, tamper-proof records of process activities. Second, the DT model, operating in collaboration with the blockchain tiers, enables real-time alignment between the manufacturing floor and its virtual twin. Third, a unified data representation is designed to transform diverse manufacturing datasets into a homogeneously structured format. Experimental results show that the proposed framework significantly enhances data authenticity while reducing the time required to map manufacturing process flows.