NATIONAL UNIVERSITY OF SCIENCE AND TECHNOLOGY

FACULTY OF ENGINEERING

DEPARTMENT OF INDUSTRIAL AND MANUFACTURING

ENGINEERING

CAD/CAM TIE 5211

GROUP 10

DIGITAL TWIN-ENABLED PRODUCTION PLANNING AND

SCHEDULING FOR CAM

GROUP MEMBERS

MERCY ZUZE N0196487B

ARTWELL MANDIZHA N0199389L

DOUGLAS T SAGONDA N0199024L

PRINCE MUTISI N0199004F

KAYLEM C JANSEN N0198274X

 1.0 INTRODUCTION
A digital twin is a digital/ virtual representation/ replica of a physical object, person, system or
process, that exists in real-time, contextualized in a digital version of its environment. While
Digital Twin can represent digital objects, they are often used to connect the physical and digital
worlds. Digital twins can help an organization simulate real situations, behaviours and
characteristics and their outcomes, ultimately allowing it to make better decisions. (Javaid, et al.,
2023)

Production planning and scheduling involve a systematic approach to ensure efficient and timely
production of goods. Digital twin-enabled production planning and scheduling for computer-
aided manufacturing (CAM) is an innovative approach that leverages the power of digital twin
technology to optimize and streamline the production process. By integrating digital twin
technology into CAM systems, manufacturers can create a virtual representation of their
production environment. This virtual model captures data from various sources, including
sensors, machines, and production systems, to provide real-time insights into the manufacturing
process. These insights can then be used for production planning and scheduling purposes.

2.0 Digital twins relative to production planning and scheduling for CAM
Digital twin technology plays a crucial role in production planning and scheduling for Computer-
Aided Manufacturing (CAM). Digital twins are related to production planning and scheduling in;

 Virtual Representation of the Production System - The digital twin is a virtual replica of
the physical production system. It captures the geometry, behaviour, and characteristics of
the manufacturing environment, including machines, equipment, and processes. This
virtual representation enables planners and schedulers to have a comprehensive view of
the production system, facilitating better decision-making.
 Real-Time Data Integration - Digital twins integrate real-time data from various sources
such as machine sensors, production systems, and supply chain systems. This data
includes information on machine performance, material availability, production status,
and other relevant parameters. By collecting and analyzing this real-time data, the digital
twin provides up-to-date insights into the production process, which can be utilized for
effective planning and scheduling.
  Simulation and Optimization - Digital twins enable simulation and optimization of
production planning and scheduling. By leveraging the virtual replica and real-time data,
planners can simulate different production scenarios, evaluate the impact of changes, and
optimize schedules accordingly. These simulations consider factors such as machine
availability, material availability, production capacity, and order priorities, resulting in
more efficient and effective production plans and schedules.
 Visualization and Analysis - Digital twins provide a visual representation of the
production system, allowing planners and schedulers to analyze and understand the
complex manufacturing processes. The virtual environment helps identify bottlenecks,
visualize production flows, and identify potential issues in the schedule. This
visualization and analysis capability enables better decision-making and adjustments to
optimize production planning and scheduling.
 Predictive Capabilities - Digital twins can leverage historical and real-time data to make
predictions and forecasts about the production process. By analyzing patterns, trends, and
performance metrics, the digital twin can predict maintenance needs, identify potential
bottlenecks, and anticipate issues that may impact production schedules. These predictive
capabilities support proactive decision-making and enable planners and schedulers to take
preventive measures to ensure smooth and efficient production.

Digital twin technology provides a virtual representation of the production system, integrates
real-time data, enables simulation and optimization, facilitates visualization and analysis, and
offers predictive capabilities. These features make digital twins an invaluable tool for production
planning and scheduling in CAM, allowing for more efficient resource allocation, reduced
downtime, improved responsiveness, and enhanced overall productivity.

2.1 Benefits of using digital twin technology in PPS for CAM

The use of Digital twin technology for PPS in CAM can be beneficial in a plethora of ways,
including;

 Real-time visibility monitoring and control - Digital twins provide real-time visibility
into the production process, enabling manufacturers to monitor the status of machines,
materials, and resources. This visibility helps in identifying bottlenecks, predicting
 production delays, and making informed decisions regarding production planning and
scheduling. For example, in the food and beverage industry, digital twins can track
parameters such as temperature, humidity, and pressure throughout the production
line, ensuring product quality and compliance with safety standards.

 Adoption of Industry 4.0 and other modern-day advanced technological systems and
allow for modularization and a seamless production and manufacturing experience.

 Optimization - Digital twins can run simulations and what-if scenarios to optimize
production planning and scheduling. By considering factors such as machine availability,
material availability, and order priorities, manufacturers can determine the most efficient
production schedule that minimizes downtime, reduces costs, and maximizes throughput.
For example, a local manufacturer can simulate assembly line layouts and test
different production sequences to optimise efficiency and minimize errors.

 Predictive maintenance - Digital twins can analyze data from sensors embedded in
machines to predict maintenance needs accurately. By identifying potential machine
failures or maintenance requirements in advance, manufacturers can incorporate them
into the production schedule, minimizing unplanned downtime and improving overall
equipment effectiveness. It allows companies to detect potential failures or maintenance
needs in advance, ensuring uninterrupted production.

 Resource allocation - Digital twins can assist in optimizing the allocation of resources,
such as machines, tools, and labour, by simulating different scenarios. By analyzing the
impact of resource allocation on production timelines and costs, manufacturers can make
informed decisions about resource utilization and ensure optimal utilization of available
resources.

 Collaboration and communication - Digital twins provide a common platform for

collaboration and communication among different stakeholders involved in production
planning and scheduling. By sharing real-time information and insights, manufacturers
can improve coordination, enhance decision-making, and align production plans with
business objectives. For example, engineers, operators, and planners can all access
the digital twin platform to share information, collaborate on process optimization,
 and make synchronized decisions which reduces errors, and improves overall
efficiency.

 Digital twins enable continuous improvement by providing data-driven insights into

production processes, by which companies can identify areas for improvement,
implement changes, and measure the impact of those changes on productivity and quality.

 Allows for easy and swift validation and verification of the necessary adjustments,
changes and alterations to any system, or object before mass production or physical
implementation.

2.2 Efficiency and Productivity Improvements

Digital twin-enabled production planning and scheduling for Computer-Aided Manufacturing
(CAM) can significantly increase efficiency and productivity in several ways;

1. This system provides a clear view of resources available in the plant and allows for
adjustments to be made based on changes in demand. This ensures that resources are
allocated in the most efficient way possible.
2. Digital twins allow “what-if” simulations. You can test different production schedules
and reallocate resources during peak demand virtually before implementing them. These
simulations can help you understand the impact on capacity.
3. Digital twins use historical data to forecast resource needs, thereby preventing overuse or
shortages.
4. It offers end-to-end visibility and traceability enable supply chain practitioners to easily
identify delays and bottlenecks by spotting patterns in the highly complex and dynamic
system.
5. During the phase of designing a manufacturing system, digital twins act as virtual
prototypes. Engineers can make adjustments and test various manufacturing simulations
or designs before finalizing a physical prototype. This iterative process helps reduce the
number of manufacturing system design iterations required, which in turn saves both time
and cost.
 6. Manufacturers can gain insights into performance indicators by creating a digital twin of
the manufacturing process. Adjustments to the digital twin can identify ways to optimize
production and reduce variances.
7. Digital twins help streamline changeovers between different production runs. By
simulating and optimizing the process, manufacturers can reduce downtime during
transitions, leading to cost savings.
8. A digital twin continuously monitors equipment performance using real-time data from
sensors and IoT devices. By analysing this data, it can predict when equipment might fail
or require maintenance. Early detection allows for timely repairs, minimizing downtime
and preventing costly breakdowns.
9. Digital twins simulate different production scenarios, including varying load levels on
equipment. By analysing these scenarios, they can recommend optimal load distributions
to maximize efficiency and minimize strain on machinery
10. Digital twins help calibrate tools and machinery by simulating adjustments and their
impact. They can optimize settings for maximum output while maintaining quality
standards. This ensures consistent performance and reduces waste
11. During factory setup or expansion, digital twins validate layout designs. They optimize
floor space, estimate inventory needs, and evaluate spatial parameters. Efficient layouts
lead to smoother workflows and better equipment utilization.

By harnessing the power of digital twin-enabled production planning and scheduling for CAM,
manufacturers can achieve higher levels of efficiency, reduce costs, improve customer
satisfaction, and drive overall productivity gains in their operations.

2.3 The challenges and limitations of implementing digital twin technology.

The technology is not flawless and will face its fair share of limitations in use and
implementation;

 Digital twins depend heavily on precise and high-quality data to produce accurate
simulations and predictions; incomplete, out-of-date, or inaccurate data can result in
decisions about production scheduling and planning that are not based on reality.
 It can be difficult to create a digital twin that faithfully depicts a complicated
manufacturing system. The difficulty of producing an accurate digital twin that can
 successfully simulate and predict outcomes increases with system complexity thereby
also increasing the skill and expertise required which may be difficult for other
companies
 Scalability issues with digital twins could arise, particularly in large-scale
manufacturing settings e.g., changes in workflow, process and organizational culture.
Making and maintaining an accurate digital twin could get harder as the
manufacturing system gets bigger and more complex.
 Sensitive information about the manufacturing process is stored in digital twins,
making them vulnerable to illegal access or cyberattacks.
 It can be difficult and time-consuming to integrate digital twins with current
production planning and scheduling systems. For the digital twin to be successful, it
must be able to exchange data with other systems and efficiently communicate with
them.
 Digital twin technology development and implementation can be expensive,
particularly for small and medium-sized manufacturing businesses with tight budgets.
It can be expensive to produce and maintain because of initial costs associated with
technology, software and experience

3.0 Case study

Below are some case studies of companies, and entities that implemented the Digital twin
technology in Production, planning and scheduling for CAM.

1. Siemens Digital Twin for Machine Tool Optimization:

Siemens, a leading technology company, implemented a digital twin solution to optimize
production planning and scheduling for machine tools. They integrated their digital twin
platform with machine tool systems to create a virtual replica of the physical
manufacturing environment. The digital twin collected real-time data from sensors
embedded in the machines, capturing information such as machine utilization, tool wear,
and process parameters.

By leveraging this data, Siemens developed advanced algorithms to simulate and optimize
production planning and scheduling. The digital twin analyzed machine performance, identified
bottlenecks, and optimized tool paths to minimize cycle times. It also predicted maintenance
needs based on the condition of the machine, reducing unplanned downtime.

The implementation of the digital twin solution resulted in significant improvements in

efficiency and productivity. Siemens achieved a 20% reduction in cycle times, a 15% increase in
machine utilization, and a 10% decrease in unplanned machine downtime. The digital twin-
enabled production planning and scheduling solution allowed Siemens to optimize their CAM
processes, leading to improved operational efficiency and increased productivity.

2. BMW's Digital Twin for Production Planning and Scheduling:

BMW, a renowned automotive manufacturer, implemented a digital twin solution to
enhance production planning and scheduling for their manufacturing facilities. They
created a virtual replica of their production systems, integrating data from various sources
such as machine sensors, manufacturing execution systems, and supply chain systems.

The digital twin enabled BMW to simulate different production scenarios and optimize their
planning and scheduling processes. It considered factors like machine availability, material
availability, production capacity, and order priorities to generate optimized production schedules.
The digital twin also provided real-time visibility into the manufacturing process, allowing
operators and planners to monitor production progress and identify potential issues.

By implementing the digital twin solution, BMW achieved remarkable improvements in

efficiency and productivity. They reduced setup times by 33%, improved production throughput
by 15%, and minimized unplanned downtime by 20%. The digital twin-enabled production
planning and scheduling solution empowered BMW to optimize its CAM operations, achieve
better resource utilization, and enhance overall productivity.

Other case studies are;

3. General Electric (GE) implemented a digital twin solution called "Brilliant Factory" in
their CAM processes. The digital twin integrated data from various sources such as
machines, sensors, and production systems to create a virtual replica of their
manufacturing facilities. This enabled real-time monitoring of production processes and
optimization of production planning and scheduling. By leveraging the digital twin, GE
 achieved a 10% reduction in downtime, improved machine utilization, and increased
overall productivity.
4. Airbus, a leading aerospace manufacturer, implemented digital twin technology in their
production planning and scheduling for CAM. They created a virtual model of their
manufacturing systems and machines, integrating data from sensors and other sources.
The digital twin allowed Airbus to simulate production scenarios, optimize schedules,
and analyze the impact of changes in demand or resources. This resulted in improved
efficiency, reduced lead times, and increased overall productivity in their manufacturing
operations.
5. Procter & Gamble (P&G), a multinational consumer goods company, implemented digital
twin technology in their production planning and scheduling for CAM. They created a
virtual replica of their production systems, integrating data from machines, sensors, and
supply chain systems. The digital twin enabled P&G to optimize production schedules,
reduce changeover times, and improve resource utilization. This led to increased
efficiency, reduced costs, and enhanced overall productivity in their manufacturing
processes.
6. Honeywell, a global technology company, implemented digital twin technology in their
CAM processes to optimize production planning and scheduling. They created a virtual
model of their production systems, integrating data from machines, sensors, and other
sources. The digital twin enabled Honeywell to simulate different production scenarios,
identify bottlenecks, and optimize production schedules. This resulted in improved
efficiency, reduced downtime, and increased overall productivity in their manufacturing
operations.

These case studies demonstrate the practical implementation of digital twins in production
planning and scheduling for CAM, resulting in significant efficiency gains, reduced downtime,
improved resource utilization, and enhanced overall productivity for manufacturing
organizations.

4.0 CONCLUSION
To summarize, the use of digital twin technology in production planning and scheduling for
CAM involves creating virtual replicas of manufacturing environments to optimize
 production processes. This innovative approach has gained significant attention in the field of
CAD/CAM due to its potential to streamline product development and improve
manufacturing efficiency. By providing real-time visibility, optimization capabilities,
predictive maintenance insights, resource allocation optimization, and improved
collaboration, manufacturers can enhance efficiency, reduce costs, and improve overall
productivity in CAM operations. It is recommended to integrate the digital twin model with
other systems, such as product lifecycle management (PLM) and manufacturing execution
systems (MES), to enable seamless data exchange and collaboration across different stages of
the product lifecycle. Despite the benefits, it is important to consider the potential challenges
and limitations associated with digital twin implementation, such as data integration and
interoperability, computational requirements, and cybersecurity considerations.

References
Javaid, M., Haleem, A. & Suman, R., 2023. Digital Twin applications toward Industry 4.0. A
Review,Cognitive Robotics,, 3(2667-2413), pp. 71-92.