Challenges in the Development of a Digital Twin for a Flexible Manufacturing Line: A Case Study

The development of digital twins for manufacturing lines represents a pivotal advancement towards the implementation of Industry 4.0, offering significant opportunities for process optimisation, enhanced operational efficiency, and cost reduction. This study aims to examine and articulate the challenges inherent in designing a digital twin for a flexible manufacturing line (FML). A case study is presented to detail the process of developing a digital twin for a real-world manufacturing line, with a focus on the difficulties encountered during its implementation. Key challenges identified include the complexity of system modelling, the reliance on historical data, and the requirement for sufficiently accurate models. The analysis highlights that tools such as the SIPOC diagram, value stream mapping, tooling matrices for machining equipment, and well-structured training programmes are instrumental in overcoming these challenges. This study provides valuable insights into best practices for designing digital twins for FML, emphasising the critical importance of early system integration, continuous testing, and iterative development. Furthermore, the research identifies specific areas where further investigations could advance the methodologies underpinning digital twin (DT) design within the manufacturing sector. The findings underscore the transformative potential of digital twins to enhance the efficiency, flexibility, and innovativeness of FML. However, they also highlight the necessity for continued technological and methodological advancements to address the challenges associated with their implementation.