Design

Digital Twins for Production

Digital Twins for Production

RAPIDZ — Resource analysis and process integration through digital twins
Christian Salzig ORCID Icon, Julia Burr ORCID Icon, Sophie Hertzog
In today’s manufacturing industry, digital twins are a key enabler for optimizing production processes and efficient resource use. However, creating digital twins is often associated with high or difficult-to-estimate costs and typically requires unknown characteristic values, such as material parameters, making practical implementation challenging. With RAPIDZ, we present a tool for creating and using digital twins that overcomes these barriers through its modular structure. The virtual modeling of physical systems enables comprehensive analysis and real-time forecasting of material flows, energy consumption and machine performance. The use of RAPIDZ increases production line efficiency, enhances flexibility and response time, and enables proactive maintenance to minimize downtime.
Industry 4.0 Science | Volume 41 | Edition 3 | Pages 6-12 | DOI 10.30844/I4SE.25.3.6
STAG — Bridging Data from Shop Floor to IT World

STAG — Bridging Data from Shop Floor to IT World

An automated mapping approach for improved access to shop floor data
Oliver Amft ORCID Icon, Dovydas Girdvainis ORCID Icon, Christoph Rathfelder ORCID Icon
Collecting data from different sources on the shop floor and making it accessible to different IT systems is one of the core tasks during the process of factory digitization. Due to the different protocols and interfaces, the data collection task comes with unique challenges. With the Sensor Technology Adapter Gateway (STAG), we present a solution that closes the gap between the shop floor and the IT system’s backend. STAG is an industry-grade middleware that automates translations between data models and protocols.
Industry 4.0 Science | Volume 41 | Edition 3 | Pages 14-22 | DOI 10.30844/I4SE.25.3.14
Transforming Customer Impulse into Procurement Action

Transforming Customer Impulse into Procurement Action

How digital twins strengthen customer orientation in supply management
Dominik Oehlschläger, Andreas H. Glas, Michael Eßig
Supply management provides an organization with the resources that it needs but does not produce itself. However, intraorganizational needs are not isolated. They ultimately serve to fulfill the demands of external (end) customers. Traditionally, supply management receives information from its internal customers, i.e. from other functional areas such as production planning, logistics, or marketing. Information on (end) customer demands reaches supply management, if at all, indirectly via these other functional areas, which often pass on information after interpreting it. This article discusses how digital twins of (end) customer demands can provide all functional areas with precise, near-real-time data.
Industry 4.0 Science | Volume 41 | Edition 3 | Pages 118-124
Virtual Exhibition as a Digital Twin

Virtual Exhibition as a Digital Twin

A framework for decision-making for virtual representations
Isger Glauninger ORCID Icon, Markus Schürmann, Matthias Mühl, Christian van Husen ORCID Icon
Transforming formats such as showrooms, laboratories or exhibitions into a virtual presence offers both opportunities and challenges. Particularly with cyber-physical systems (CPS), which rely heavily on user interaction, extensive adaptations must be made in order to maintain their purpose and function virtually. As part of this research project, digital solutions from different technologies and fields of application were transferred to a virtual exhibition. On this basis, the influence of the digital transformation on the interactivity and emulation of the solutions was analyzed. This article presents a framework that supports practitioners in the implementation of virtual representations.
Industry 4.0 Science | Volume 41 | Edition 3 | Pages 110-116
Strategic Product Planning Model

Strategic Product Planning Model

Digital twins for circular products and production processes
Iris Gräßler ORCID Icon, Sven Rarbach, Benedikt Grewe
Strategic Product Planning must adapt to current challenges such as circular economy, digital business models and interdisciplinarity. Established process models, for example, can only be applied to Product-Service Systems to a limited extent. This article presents a new SPP model developed through an analysis of 230 existing approaches and enhanced by the integration of digital twins, enabling continuous feedback throughout the entire product life cycle. This allows product monitoring and dynamic adjustments to the SPP. The model adopts an agile, iterative framework consisting of five cyclical key activities, guided by five control points aligned with increasing levels of maturity. By factoring in circularity from the outset, the model promotes resource-efficient products and production processes. Its emphasis on flexibility, information circularity and sustainability ensures future value and adaptability across industries of the proposed SPP model.
Industry 4.0 Science | Volume 41 | Edition 3 | Pages 24-31 | DOI 10.30844/I4SE.25.3.24
Hybrid Learning Landscapes for Technical Concepts

Hybrid Learning Landscapes for Technical Concepts

The digitalization of training via practical concepts and targeted networking
Sebastian Anselmann ORCID Icon, Jessica Wädt, Uwe Faßhauer ORCID Icon
The Länder- und Phasenübergreifende Interface (LPI) (engl. Cross-Regional and Cross-Phase Interface) promotes the sustainable digitalization of vocational and technical education through the systematic provision of expertise and innovative networking formats. The focus is on hybrid learning landscapes (HLL), which interlink physical and digital learning spaces to create individualized, practical learning environments. Innovative approaches such as learning factories, VR/AR and learning analytics are integrated.
Industry 4.0 Science | Volume 41 | Edition 3 | Pages 126-132
Open-Source and Cost-Effective Digital Twin

Open-Source and Cost-Effective Digital Twin

A case study with two weeks to succeed
Shantall Cisneros Saldana ORCID Icon, Sonali Pratap, Parth Punekar, Sampat Acharya, Heike Markus ORCID Icon
Digital Twin (DT) adoption remains a challenge due to high costs, complexity and lack of skills. This study proposes a cost-effective, TRL 5-validated DT model that can be built using open-source and office suite tools within just two weeks. Integrating real-time sensor data, predictive analytics, anomaly detection and notification, the model improves efficiency and sustainability in agriculture. Even with cloud service constraints, the system delivers a 7.76% average relative error and rapid, automated notifications. The findings show how open-source in combination with common commercial tools technologies can make advanced digital tools accessible to all, creating scalable, human-centered, and affordable solutions in line with Industry 5.0 principles.
Industry 4.0 Science | Volume 41 | Edition 3 | Pages 62-68 | DOI 10.30844/I4SE.25.3.62
Digital Twins in Logistics

Digital Twins in Logistics

Opportunities and barriers during implementation
Benjamin Gorgas ORCID Icon, Jan Kliewer ORCID Icon, Tobias Marc Wringe, Maximilian Bähring ORCID Icon, Frank Straube, Rüdiger Zarnekow
Digital Twins offer great potential for increasing efficiency in logistics. Digital supply chain twins (DSCT) enable data-driven decisions and optimize processes at location and network level. A study conducted during an expert workshop shows that companies are interested in DSCT, but challenges such as data quality, cross-actor data exchange and interoperability are hindering their widespread implementation. While pilot projects exist, market penetration remains low. Successful implementation requires standardized interfaces and contractual frameworks for data exchange. As a result, DSCT can make logistics networks more resilient and sustainable in the long term.
Industry 4.0 Science | Volume 41 | Edition 3 | Pages 34-40 | DOI 10.30844/I4SE.25.3.34
Functional Safety and Cyber Security in the Process Industry

Functional Safety and Cyber Security in the Process Industry

A tension between stability and agility
Thimmo Kugele, Claudia Nowak, Arno Götz, Alexander Lawall ORCID Icon
Functional safety (safety) and cyber security (security) are key aspects of modern industry and technology. Safety aims to minimize risks posed by system malfunctions. This includes measures to protect people and the environment from failures and errors within systems. Security focuses on protecting systems and networks from digital attacks. The primary security objectives include ensuring confidentiality, integrity, and availability. A joint consideration of safety and security is essential for the future of the process industry, as both the physical safety and digital integrity of modern systems must be ensured. In industrial practice, this creates a field of tension: measures to enhance security can negatively impact safety and vice versa. This article analyzes relevant standards and regulations, presents key approaches for the integrated consideration of safety and security, and highlights areas of further research.
Industry 4.0 Science | Volume 41 | 2025 | Edition 2 | Pages 87-93
Why Moving Toward a Circular Economy Is Crucial

Why Moving Toward a Circular Economy Is Crucial

The ten R-Strategies of sustainable management
Ralf T. Kreutzer
As environmental challenges such as climate change and resource scarcity intensify, with Earth Overshoot Day highlighting overconsumption, the circular economy emerges as a crucial solution. Legislation at the national and EU level obliges companies to become more sustainable. Simultaneously, the circular economy strengthens economic resilience, promotes innovation and creates competitive advantages. However, the impact on the labor market is controversial, as fewer primary resources and new products are needed. Sustainable corporate management requires a balanced consideration of the triple bottom line: Planet, People, and Profit, treating each as equally important. In contrast to the linear economy, the circular economy follows the ‘cradle to cradle’ principle and integrates the ten R-Strategies of sustainability. These strategies range from refuse (avoidance) and reduce (reduction) to recycling and repurpose (reuse). Companies should identify which strategies can be swiftly ...
Industry 4.0 Science | Volume 41 | 2025 | Edition 2 | Pages 68-76
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