A Digital-Twin-Enabled AI-Driven Adaptive Planning Platform for Sustainable and Reliable Manufacturing

The manufacturing systems face growing demands due to the instability of the market, the demanding sustainability policies, and the high rate of old equipment, but traditional planning structures are mostly fixed and deterministic, leading to the inefficiency of joint optimization of operational stability and environmental sustainability in unpredictable situations. This research proposed and empirically tested an artificial-intelligence-based adaptive planning platform, which combines a physics-based Digital Twin (DT) and a Pareto-conditioned Multi-Objective Proximal Policy Optimization (MO-PPO) algorithm to be able to co-optimize reliability and sustainability indicators in real-time. The platform reinvents manufacturing planning as a Constrained Multi-Objective Markov Decision Process (CMDP), optimizing an Overall Equipment Effectiveness (OEE) and energy carbon intensity as well as material waste, and strongly adhering to operational restrictions. The study utilizes a four-layer cyber–physical architecture, which includes an edge-based data acquisition layer, a high-fidelity stochastic simulation engine that is calibrated via Bayesian inference, a graph attention network-based state-encoding layer, and a closed-loop execution loop that runs with 60 s long planning cycles. In this study, a statistically significant enhancement was shown in 10,000 stochastic simulation experiments and a 12-week industrial pilot deployment: 96.8% schedule performance, 84.7% OEE, 16.5% cut in specific energy usage (2.38 kWh/kg), 17.1% reduction in material-waste rate (6.8%), and 21.4% enhancement in carbon effectiveness, outperforming all baseline strategies (p = 0.001). The analysis showed that there was a surprising synergistic correlation between waste minimization and OEE enhancement (r = −0.73), and 34.1% of overall OEE improvement could be explained by sustainability strategies. This study provides a robust framework for adaptive, resilient, and eco-friendly manufacturing processes in line with Industry 5.0 ideologies.