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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
Training in the Industrial Metaverse

Training in the Industrial Metaverse

Buzzword or opportunity?
Leon Schellhammer ORCID Icon, Lucas Waag, Mert Cumert, Dieter Uckelmann ORCID Icon
Metaverse-based training programs offer a realistic and risk-free learning environment that is particularly valuable in industrial contexts, e.g. in immersive training and the simulation of workflows. Challenges remain in the areas of data protection, technological acceptance and integration into existing systems. Using a carefully crafted questionnaire, four expert interviews were conducted to investigate whether the metaverse can innovate training programs effectively and lastingly. Its standardized format yields comparable, reliable data while allowing for an accurate evaluation of the results.
Industry 4.0 Science | Volume 41 | 2025 | Edition 2 | Pages 102-108
Optimizing the Budgeting Process with Digital Twins

Optimizing the Budgeting Process with Digital Twins

Dashboards and process mining for process-oriented performance measurement
Bettina C. K. Binder ORCID Icon, Frank Morelli ORCID Icon
Traditional budgeting often resembles a marathon full of spreadsheets, manual reconciliations and time-consuming data collection. However, modern companies need agile, data-driven solutions that allow for transparency, efficiency and strategic foresight. Digital technologies such as digital twins, dashboards and process mining initiate this possibility: they transform the budgeting process from a static set of figures to a dynamic, simulation-capable management tool. Instead of getting lost in detailed work, companies can use them to analyze processes in real time, simulate scenarios and make well-informed decisions.
Industry 4.0 Science | Volume 41 | Edition 2 | Pages 52-58
Intelligent Load Carrier Management

Intelligent Load Carrier Management

AI-supported monitoring and reduction of losses in logistics
Dominik Augenstein, Lea Basler
Load carriers are essential for transporting manufactured parts in manufacturing companies. Despite their ‘simplicity’, they are usually expensive to purchase as they are manufactured expressly to fit purpose. While tracking methods such as GPS tracking can be used to prevent the loss of load carriers, this is associated with monitoring costs and presents challenges with regard to data protection as soon as the work performance of intralogistics employees is monitored. Assigning load carriers to designated clusters and monitoring these clusters provides an effective solution—without drawing conclusions about employee performance. Furthermore, artificial intelligence can optimize this approach whilst also deterring the theft of load carriers.
Industry 4.0 Science | Volume 41 | 2025 | Edition 2 | Pages 78-84
Boosting Competitiveness in Small Batch Production

Boosting Competitiveness in Small Batch Production

Scalable and flexible body-in-white production line with collaborative mobile robots
Walid Elleuch, Tadele Belay Tuli ORCID Icon, Martin Manns ORCID Icon
Due to the higher customization of products to customer groups and needs, body-in-white manufacturing industries are facing higher variant assembly at the later stages of the production line, thus increasing production costs per unit. Flexible production processes that involve flexible material flows, non-rigid manufacturing sequences, and the automatic reconfiguration of tools are regarded as the pillars of a resilient production system. This article presents a conceptual solution for flexible Body-in-White sheet metal production with autonomous collaborative robotic systems to make product costs affordable for a higher competitive advantage.
Industry 4.0 Science | Volume 41 | Edition 2 | Pages 60-67
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