Exploring digital modeling in line manufacturing implementation and management: reinterpreting human agency as a critical (success) factor

This study investigates the limitations of digital modeling and digital twin technologies in line manufacturing, emphasizing the critical role of human agency in successful implementation. Using a multiple case study approach, we analyzed eleven implementation projects across seven manufacturing firms. The findings show that while digital tools support equipment-related decision-making and process optimization, they often fall short in capturing tacit knowledge, experiential expertise, and adaptive judgment. Projects with stronger integration of employee competencies, particularly in contexts of process variability and organizational change, demonstrated more effective outcomes. Overreliance on digital tools can obscure the contributions of human actors, leading to inefficiencies and implementation challenges. We argue that implementation strategies must move beyond purely technological solutions to explicitly incorporate human-centric capabilities. This research advocates for a reconfiguration of current digitalization frameworks to explicitly recognize and embed human-centric capabilities in the design and deployment of advanced manufacturing systems.