Towards the Development of a Digital Twin for a Sustainable Mass Customization 4.0 Environment: A Literature Review of Relevant Concepts
Abstract
:1. Introduction
1.1. Industry 4.0 and Mass Customization
- The need for the development of entirely new business models [38] and their associated business processes. According to [39], a business model focuses on the “what” side of value creation, while a business process model focuses on the “how” side of value creation. As customers are integrated into the value creation process by defining and configuring individual solutions a tool is needed to accomplish this [40]. In the age of Industry 4.0, this refers to:
- The support of a manufacturing environment should be suitable to be scalable at no extra cost [45,46,47]. This scalability refers to the production system reconfiguration that takes place through the integration of plug-and-produce, fully automated, digitized, highly cost efficient, smart new manufacturing units [7]. This calls for the use of new efficient re-configurable manufacturing methods such as the CPS [48], where its real time, production coordination capabilities allows boosting customer satisfaction by economically producing customized products [49,50]. These coordination capabilities come from the efficient processing of a vast amount of information (coming from tightly connected sensors, controllers, manufacturing systems, etc.), that later on is transformed into optimized decisions [51].
1.2. Digital Twins
- Industry 4.0: a DT requires a set of technologies needed for its implementation including, but not limited to, simulation methods, communication protocols, and the core technologies of Industry 4.0 [60], a concept that has emerged as a manufacturing enabler to achieve the desired time-to-market reduction [70];
- Mass customization: the demand for highly individualized products with shorter lifestyles drives modern manufacturing systems to focus on the use of information technology-based manufacturing systems [71], such as the so-called data-driven Digital Twins [58]. A DT of a manufacturing system in the form of a simulation and data model [61] that synchronizes both the physical and digital worlds [72] can be used to address the issue of manufacturing customized products [2], as it makes the deployment of the required flexible and reconfigurable manufacturing system possible [73];
- Sustainability: DTs may be utilized to address these sustainability challenges [10]. For example, social sustainability requires the integration of human skills with technology [76], and the improvement of the environmental and social factors of smart manufacturing may conflict with the economic factor [35]. In [77] the authors depict a sustainable digital twin (SDT) framework for shifting from a static sustainability assessment to a digital twin (DT)-based and Internet of Things (IoT)-enabled dynamic approach;
- Value Creation: within the DT context, the importance of the physical world resides in the fact that it is there where the actual value-creation process takes place [66].
1.3. Digital Twins and Small and Medium-Sized Enterprises
2. Research Gaps
2.1. Sustainability and Manufacturing Efficiency
2.2. Sustainability and Industry 4.0
- Virtual Reality (VR)/Augmented Reality (AR) technologies lead to sustainability via better training and knowledge [124];
2.3. Sustainability and Value Creation
Sustainability and … | References |
---|---|
Manufacturing Efficiency | [4,88,89,90,91,92,93] |
Mass Customization and Industry 4.0 | [93,96,97,99,100,101,102] |
Industry 4.0 | [103,104,105,106,107] |
Smart Manufacturing | [99,108,109,110,111,112,113,114] |
Virtual/Augmented Reality/Cloud Manufacturing | [115,116,117,118,121,124] |
Value Creation | [4,126,127,128,129,130,131,132,133] |
2.4. Research Features
- (1)
- The SMC4.0 business environment refers to a business model that reflects the economic benefits of achieving sustainability (in a context of manufacturing efficiency), plus the environmental and social impacts that will guarantee durable competitiveness;
- (2)
- The SMC4.0 manufacturing environment refers to a rapid responsive (quick and profitable), service-oriented (ability to fulfill the demand for highly customized products) manufacturing model.
3. Sustainable Value Creation
3.1. The Sustainable CPPR 4.0 Framework
- Each quadrant of the framework presents the questions pertaining to each value domain, i.e., the WHO of value delivery; the WHAT of value proposition; the WHAT/WHEN/WHERE/HOW of value creation; the WHY of value capture;
- The answers to these questions, for each value domain, can be found in Table 2;
- The arrows pointing direction (in Figure 3) indicates the customer (clockwise, solid line) and supplier (counterclockwise, dotted line) standpoint, when reading the framework.
3.2. The Value Creation Relationships
Transformation Activities Sequence | Sequence Option # | ||||||
---|---|---|---|---|---|---|---|
Product | M1 | M2 | M3 | M4 | M14 | M23 | |
PA | 1st | 2nd | 1 | ||||
1st | 2nd | 2 | |||||
1st & 2nd | 3 | ||||||
PB | 1st | 2nd | 3rd | 1 | |||
1st | 2nd | 3rd | 2 | ||||
1st | 3rd | 2nd | 3 | ||||
1st | 3rd | 2nd | 4 | ||||
2nd | 1st & 3rd | 5 | |||||
1st & 3rd | 2nd | 6 | |||||
PC | 1st | 2nd | 3rd | 4th | 1 | ||
1st | 2nd | 3rd | 4th | 2 | |||
1st | 4th | 2nd & 3rd | 3 | ||||
1st | 4th | 2nd & 3rd | 4 | ||||
2nd | 3rd | 1st & 4th | 5 | ||||
1st & 4th | 2nd & 3rd | 6 |
3.3. The Value Creation Abilities
- Collaboration, the ability to work together by adjusting the individual behavior of the involved partners. This is possible when the means to negotiate common benefits and risks sharing are in place.
- Coordination, the ability to work in a harmonious way when pursuing a goal that is common to all of the involved partners. This is possible when the means to match individual actions with common decision-making processes are in place.
- Cooperation, the ability to work for a common benefit in terms of an objective that is feasible to all of the involved partners. This is possible when the means to align the individual operational levels with the common strategic levels are in place.
- Communication, the ability to share key and relevant information to the rest of the involved partners. In this case, the involved partners refer to the smart products, process, and resources. In the case of information, we propose the definition proposed by [143]:
- Information: data (detected signal that shows a non-random quantified pattern) that have been evaluated to have relevance and used for establishing a course of action to implement defined objectives.
From the DT perspective, this means that there must be a mechanism in place that allows the smart products, processes, and resources “to talk among themselves and understand each other”, with the purpose of establishing a common objective. In Figure 8, the “ontology and semantics” element represents the means through which the DT allows interactions of the elements of the physical world. - Collaboration, the ability to work together by adjusting the individual behavior of the involved partners. This is possible when the means to negotiate common benefits and risks sharing is in place. In the case of behavior, we propose the definition proposed by CIMOSA, the Computer Integrated Manufacturing–Open Systems Architecture [144], when referring to the behavior of a process:
- Behavior: defined by a set of procedural rules that dictate how actions/activities need to be done/executed. This behavior is intended for the achievement of some objective, under some constraints, using some resources. A procedural rule can be in the form of a triggering condition (i.e., a system state) or an event (that is, a solicited request/unsolicited real-world happening which initiates the execution of an action/activity).
From the DT perspective, this means that there must be a mechanism in place that allows the smart products, processes, and resources “to define” a combined set of procedural rules that “guides” the pursuing of the common objective, within the upper limit of the benefits and the lower limit of the risks (Figure 9). - Coordination, the ability to work in a harmonious way when pursuing an objective that is common to all of the involved partners. This is possible when the means to match individual actions with common decision-making processes are in place. In the case of decision-making, the structure of a GRAI net (Figure 10, Table 6), which is basically a Petri net with special graphical symbols [145], could be used to represent it. From the DT perspective, this means that there must be a mechanism in place that allows the smart products, processes, and resources “to visualize” the impact of the individual decision-making processes, therefore, the next action/activity that needs to be done/executed can be determined properly.
- Cooperation, the ability to work for a common benefit in terms of a goal that is feasible to all of the involved partners. This is possible when the means to fit/integrate the individual contributions with the overall result are in place. From the DT perspective, this means that there must be a mechanism in place that allows the smart products, processes, and resources, “to integrate” their individual contributions, so the placing (where)/timing(when) of the next action/activity that needs to be done/executed can be determined properly.
4. The SMC4.0 Information Flow Model
Sustainable CPPR 4.0 | Mass Customization Business Processes | Make-to-Order | |||||
---|---|---|---|---|---|---|---|
[131] | [147,148] | [146] | [149,150] | [34] | [155] | ||
Subcycles | Activities | ||||||
Value Proposition | Design | Product development/design | Development; i.e., product development/design | Step #1: personalization | Design | Design new products | Conduct market research |
Analyze product technology | |||||||
Develop prototype | |||||||
Design new components | |||||||
Modify standard design to meet customer requirements | |||||||
Obtain customer approval for new design | |||||||
Develop bill of material and process plans | |||||||
Value Capture | Sell | Order taking | Interaction; i.e., order placement | Step #2: purchasing | Order processing | Respond to customer inquiry | |
Create sales order | Develop specifications | ||||||
Determine delivery | |||||||
Determine price | |||||||
Check customer credit | |||||||
Receive customer approval | |||||||
Value Creation | Make/Assembly | Order fulfillment management | Production; i.e., fabrication/assembly | Steps #3 and #4: manufacturing | Production | Production planning and control | |
Materials management | |||||||
Fabricate parts | |||||||
Assemble products | |||||||
Inspection, testing, rework | |||||||
Inventory finished products | |||||||
Value Delivery | N/A | Order fulfillment realization | Logistics; i.e., packing/delivery | Step #5: delivering | Distribution | Ship products to distribution center | |
Pick products for customer orders | |||||||
Ship products and invoice customers |
Managerial Implications
5. Concluding Remarks
5.1. Future Research
- A mechanism for smart products, processes, and resources, “to talk among themselves and understand each other” (Communication);
- A mechanism for smart products, processes, and resources, “to define” a combined set of procedural rules that “guides” the pursuing of the common objective (Collaboration);
- A mechanism for smart products, processes, and resources, “to visualize” the impact of the individual decision-making processes (Coordination);
- A mechanism for smart products, processes, and resources, “to integrate” their individual contributions (Cooperation).
5.2. Conclusions
Funding
Informed Consent Statement
Conflicts of Interest
Appendix A
- From an economic point of view, Industry 4.0 technologies can reduce set-up times, achieve shorter lead times, reduce labor and material costs, increase production flexibility, achieve higher productivity, and enhance customization [166];
- From a social point of view, Industry 4.0 technologies can support employee health and safety, by taking over monotonous and repetitive tasks resulting in higher employee satisfaction and motivation [21].
- Economic sustainability attributes; end poverty (EP), decent work and economic growth (DWEG), industry, innovation, and infrastructure (III), reduced inequalities (RI), and partnerships for the goals (PG).
- Social sustainability attributes; end hunger (EH), good health and well-being (GHW), quality education (QE), gender equality (GE), and peace, justice and strong institutions (PJSI);
- Environmental impact attributes; clean water and sanitation (CWS), affordable and clean energy (ACE), sustainable cities and communities (SCC), responsible consumption and production (RCP), climate action (CA), life below water (LBW), and life on land (LL).
Appendix B
Mass Customization Structural Elements | Range of Values | Rn * | From | To | Rt ** | |
---|---|---|---|---|---|---|
0 | 1 | |||||
Level of customization (lc) | Standard product | Personalized product | 1 | lc | lowoq | + |
Level of OW/OQ (lowoq) | 100% Common features | 100% Unique features | 2 | lc | lpva | + |
Level of product’s complexity (lpcplx) | Few operations/easy to execute | Lot of operations/hard to execute | 3 | lpva | lpvo | − |
Level of production variety (lpva) | A small number of models | A large number of models | 4 | lowoq | lpcplx | + |
Level of production volume (lpvo) | A few units produced | A lot of units produced | 5 | lowoq | lcomp | + |
Level of system’s reconfiguration (lsr) | Hard-connected workstations/rigid flow | Loose-connected workstations/flexible flow | 6 | lpcplx | ltech | + |
Level of equipment technification (ltech) | Specialized-use equipment | General-use equipment | 7 | lpcplx | lsr | + |
Level of labor skill (ls) | Single-task specialist | Multiple-task generalist | 8 | lpcplx | ls | + |
Level of components (lcomp) | Small number of components | Large number of components | 9 | ltech | lcomp | + |
Level of customization (lc) | 100% Common features | 100% Unique features | 10 | ltech | ls | + |
Level of OW/OQ (lowoq) | Few operations/easy to execute | Lot of operations/hard to execute | 11 | lsr | lpvo | − |
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VALUE | ECONOMIC | ENVIRONMENTAL | SOCIAL |
---|---|---|---|
Proposition | Economic value | Functional value | Social value |
Creation I | Key Activities | Production | Governance |
Key Partners | Suppliers | Local Community | |
Creation II | Key Resources | Materials | Employees |
Key Partners | Suppliers | Local Community | |
Delivery | Customers’ Segments & Relationships | Use & End-of-Life Cycle | Society Culture |
Distribution Channels | Distribution | Scale of Outreach | |
Capture | Value Stream | Environmental Benefits | Social Benefits. |
Cost Structure | Environmental Impacts | Social Impacts | |
Sustainability Indicator | Product Innovation | Emission reduction | Human diversity |
Risk management Profit | Natural resource management Environmental management | Human rights Labor relations | |
Cost savings | Environmental assessment | ||
Eco-Environmental | Energy efficiency | X | |
Life cycle management | |||
Socio-Environmental | X | Client safety & health | |
Global climate change | |||
Socio-Economic | Customer Ethics | X | Security |
Product | Transformation Activities Sequence | Sequence Option # | |
---|---|---|---|
M4 | M14 | ||
PA | 2nd (50%) | 1 | |
2nd (50%) | 2 | ||
1st & 2nd (100%) | 3 | ||
1/3 | 2/3 | # sequences fulfilled | |
PB | 3rd (33.33%) | 1 | |
3rd (33.33%) | 2 | ||
3rd (33.33%) | 3 | ||
3rd (33.33%) | 4 | ||
1st & 3rd (66.66%) | 5 | ||
1st & 3rd (66.66%) | 6 | ||
2/6 | 4/6 | # sequences fulfilled | |
PC | 4th (25%) | 1 | |
4th (25%) | 2 | ||
4th (25%) | 3 | ||
4th (25%) | 4 | ||
1st & 4th (50%) | 5 | ||
1st & 4th (50%) | 6 | ||
2/6 | 4/6 | # sequences fulfilled |
Question Posed | Decision Criteria | |
---|---|---|
Smart products | How many transformation activities are left in my manufacturing route? | Select the resource that provides the most of these transformation activities. |
Smart resource | How many transformation activities can I provide? | Select the product that consumes the most of these transformation activities. |
Smart process | Which combination of product and resource advances my manufacturing route completion the most? | Select the combination that advances the most manufacturing routes. |
Elements | Terminology |
---|---|
Model m | Structure and parameters describing the Decision problem d. |
Decision variable dv | A vector of the variables of the Decision problem d. |
Decision frame d | Set of all solutions Sd of the decision center for a given Decision problem d. |
Decision center requests r | Restrictions issued/constraints imposed on the solution space by a decision center. |
Feasible solution Sf | For a given Model m, Decision frame d, and Decision center requests r, a set of all instantiations of Decision variable dv. |
Evaluation function ef | Function which assigns a real value to each feasible solution sf. |
Value function vf | Function which combines the values of all Evaluation functions ef, of several Decision objectives do, to define one scalar value for a given Feasible solution sf. |
Decision objective do | Minimization or maximization of an Evaluation function ef. |
Decision rule dr | For a given Model m, Decision frame d, Decision center requests r, an algorithm which finds a good Feasible solution Sf with respect to the Decision objective do. |
Mass Customization Structural Elements [134] | MTO Business Model [155] | ||
---|---|---|---|
SUBCYCLES | ACTIVITIES | ||
Level of customization | Design | Design new products | Conduct market research |
Level of OW/OQ | Analyze product technology | ||
Level of product’s complexity | Develop prototype | ||
Design new components | |||
Modify standard design to meet customer requirements | |||
Obtain customer approval for new design | |||
Develop bill of material and process plans | |||
Level of production volume | Production | Production planning and control | |
Level of production variety | Materials management | ||
Level of technification | Fabricate parts | ||
Level of labor skill | Assemble products | ||
Level of system’s reconfiguration | Inspection, testing, rework | ||
Level of components/raw materials | Inventory finished products |
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Martínez-Olvera, C. Towards the Development of a Digital Twin for a Sustainable Mass Customization 4.0 Environment: A Literature Review of Relevant Concepts. Automation 2022, 3, 197-222. https://doi.org/10.3390/automation3010010
Martínez-Olvera C. Towards the Development of a Digital Twin for a Sustainable Mass Customization 4.0 Environment: A Literature Review of Relevant Concepts. Automation. 2022; 3(1):197-222. https://doi.org/10.3390/automation3010010
Chicago/Turabian StyleMartínez-Olvera, César. 2022. "Towards the Development of a Digital Twin for a Sustainable Mass Customization 4.0 Environment: A Literature Review of Relevant Concepts" Automation 3, no. 1: 197-222. https://doi.org/10.3390/automation3010010