Flexible Manufacturing Systems through Integration of Asset Administration Shell and OPC UA with PLC

The increasing demand for flexible and interoperable manufacturing systems necessitates the integration of digital technologies to enable real-time adaptability and data exchange. This research presents a methodology leveraging Asset Administration Shell (AAS) as a central enabler for smart manufacturing. By transitioning from static (Type 1) to reactive (Type 2) AAS and outlining a pathway to proactive (Type 3) AAS, key challenges in creating flexible systems are addressed. A system architecture integrating AAS with OPC Unified Architecture (OPC UA) and Programmable Logic Controllers (PLCs) is developed, enabling real-time synchronization. This modular framework aligns with Industry 4.0 principles, supporting scalable and adaptive manufacturing solutions.