The premise of this initiative is to accomplish an end-to-end smart manufacturing by fully integrating a scalable and resilient digital thread across the ecosystem. This will be achieved by connecting the dots between the multitude of enterprise systems and coordinating information flow between people, process and technology to synthesize data and derive actionable results.

The Connected Factory Digital Twine (CFDT) is an end-to-end process management framework for smart manufacturing that encompasses all activities in the value chain from procurement, linear process optimization, robotic activities, logistics and warehousing. It will serve as a powerful tool to streamline and optimize the entire manufacturing process by providing full visibility, enabling real-time decision-making, and facilitating collaboration between different stakeholders.

It will be based on utilization of Numorpho’s Digital Twine World Model (DTWM) Reference Architecture will ensure the interoperability and scalability of the solution, making it modular and capable of adapting to changing business needs and technological advancements. The three aspects of manufacturing that it will account for are:

1. Provisioning
2. Commissioning, and
3. Mobilization

and they are detailed in this whitepaper.

TABLE OF CONTENTS

• The Digital Twine World Model (DTWM) Reference Architecture
• Composable Architecture
  1. Connecting the Dots
  2. Data Engineering
  3. Actionable Intelligence
  4. Augmented Rendering
• Showcase Implementation @MxD – Discrete Test Bed
  • Problem Statement
  • Solution Definition
  • Relevance to MxD
  • Programmatic Goals
  • Project Objective
  • Use Cases
  • Scope of Work
  • Partnership Model
  • Process Flow Diagram
  • Process Orchestration
    • Inbound Processes (Provisioning)
    • Manufacturing Processes (Commissioning)
    • Outbound Processes (Mobilization)
• Summary
• References
  • Microsoft’s Defense and Intelligence Business Unit
  • Microsoft’s Federal Business Unit
  • Microsoft’s Industry Cloud practice
  • Oqton’s Manufacturing Operating System
  • PTC’s Infinity Loop Model Based Digital Thread
  • Siemens Mendix
  • Siemens Mindsphere

THE DIGITAL TWINE WORLD MODEL (DTWM) REFERENCE ARCHITECTURE

Numorpho’s  DTWM reference architecture provides a comprehensive framework for organizations to achieve a Smart Manufacturing mindset to enable continuous improvement, transformation, and innovation via the use of digital technologies. Embracing smart manufacturing is critical for organizations looking to thrive in the digital era, as it enables a long-term outlook on the art of the possible and drives ongoing improvement and innovation. By adopting the DTWM reference architecture, organizations can develop a robust strategy for transforming their manufacturing operations and achieving their goals in the digital era.

The DTWM Reference Architecture as shown in the interaction diagram below enables upstream, midstream and downstream activities to be concerted in the realms of the physical and the digital by enabling core meta data to be dynamically referenced based on need, availability, security and permissions.

We will utilize our Digital Twine reference architecture to enable the blueprinting of the entire process and orchestrate the pull-push of data between the systems to enable effective collaboration and cooperation between the different constituencies of the ecosystem – upstream, midstream and downstream.

COMPOSABLE ARCHITECTURE

Composable architecture refers to a design approach that enables the creation of complex systems by combining smaller, more specialized components or modules. The idea behind composable architecture is to break down a system into smaller, independent components that can be easily assembled and reassembled to create different configurations or combinations of functionality.

The solutioning for the Connected Factory Digital Twine (CFDT) will be comprised of three parts:

1. FOUNDATION comprising of the hardware stack, the data store, cloud provisions elements and business intelligence tools.
2. ENGINEERING PROCESS consisting of tools to manage the throughput, transfer of data and the integration of synthetic information.
3. ORCHESTRATION made up of coordinating the end-to-end activities to enable actionable intelligence.

Overall, these three parts will work together to provide a comprehensive solution for connected manufacturing, allowing for improved coordination and collaboration across the manufacturing enterprise, enabling:

1. CONNECTING THE DOTS

Shown below is the representation of the DTWM reference architecture to showcase the interactions in Connected Manufacturing.

2. DATA ENGINEERING

For the CFDT, data engineering pertains to:

• Inbound Processes – capacity planning activities to ensure that the procurement of raw materials is continuous and based on need,
• Manufacturing Processes – commissioning of people and equipment utilizing robotic processes and Industry Internet of Things to maintain optimized thruput, and
• Outbound Processes – operations and mobilization of the product line using logistics and efficient inventory and warehouse management.

so that all activities are connected, optimized and harmonized.

3. ACTIONABLE INTELLIGENCE

Actionable intelligence (converting meaning to motion) based on data-driven insights is used to guide decision-making throughout the product development process. For CFDT, robotic processes on the manufacturing floor will be controlled for safety and predictive behavior so that the production process can run smoothly and efficiently. In addition, the data collected from these processes will be analyzed in real-time to detect any anomalies or potential issues before they become problems.

This will enable prescriptive maintenance to be performed, further increasing productivity and reducing downtime. The data collected will also be used to continuously optimize the manufacturing process, reducing waste and improving quality. Overall, the goal is to create a closed-loop system where data is continuously collected, analyzed, and used to improve the manufacturing process.

By analyzing data and monitoring key metrics, we can continually improve the performance and functionality to ensure that they meet the needs of our customers and deliver the desired outcomes.

4. AUGMENTED RENDERING

Augmented Rendering for the Connected Factory Digital Twin is the use of advanced visualization techniques to create realistic representations of the factory and its processes, which can be used to aid in decision making, training, and troubleshooting. This involves creating virtual 3D models of the factory and its equipment, which can be used to simulate different scenarios and optimize processes.

Augmented rendering can also be used to create virtual training environments for employees, allowing them to practice operating equipment and handling different situations in a safe and controlled setting.

Additionally, augmented rendering can be used to visualize real-time data from sensors and other sources, allowing for quick identification and resolution of issues.

SHOWCASE IMPLEMENTATION @MxD

As a proof of concept, we propose to upgrade an existing manufacturing cell on MxD’s factory floor that showcases an integrated end-to-end manufacturing pipline.

Problem Statement

The Covid-19 pandemic has highlighted the need for manufacturers to rapidly evaluate different production scenarios, such as increased throughput and optimizing operations for reduced availability of workforce, without interrupting ongoing production. However, critical component manufacturers cannot afford to shut down operations for unproven changes.

Solution Definition

This project aims to use a digital twin to prevent process shutdowns due to material shortages and to virtually optimize robot control systems without interrupting production.

The project will build an automated discrete manufacturing cell incorporating these goals for demonstration, education, and use case testing purposes, with the intention that it will be used by the manufacturing community long after project completion.

It will be built modularly so that process options can be removed/updated and new processes added to the connected value chain of the platform.

MxD Relevance

MxD’s core mission is to transform American manufacturing, by fully integrating the digital thread across the manufacturing enterprise to reduce overall manufacturing costs, stabilize and grow the manufacturing industrial base and improve US competitiveness through the world. It does this by utilizing DoD appropriated funds in Strategic Investment Projects (SIP) to showcase tenets of smart manufacturing and its connected thread related to provisioning, commissioning, and mobilization. It touches all aspects of digital driving physical for enabling design for manufacturability, IoT gateways and edge services for connected data streaming, implications of supply chain and cyber security.

MxD creates blueprints, guidebooks and even complete solutions in a box (like the one for cybersecurity) as outcomes of these initiatives that are accomplished using a partnership model where large companies (tier 1 members) collaborate with institutions and schools (tier 2 members), and start ups (tier 3 members, like Numorpho Cybernetic Systems) to ideate, iterate, design and develop these solutions that could then be replicated in real settings for accomplishing Industry 4.0 standards in the new paradigm of manufacturing.

For this project, we will utilize lessons learned and best practices from prior and current SIP initiatives, our understanding of MxD’s go-forward model based on the several proposal teaming meetings we have been part of, and some of our recent exposure via MxD to DoD related solicitations from:

• MII (Manufacturing Innovation Institute) for the Remote Manufacturing Point of Need challenge
• DIU (Defense Innovation Unit) article of interest for Digital Engineering and Manufacturing of Composite Structures.

This is represented in the following infographic:

Programmatic Goals

1. Demonstrate the benefits of using a Digital Twin in formulating scenarios and response plans, particularly in emergency situations. The objective is to explore how a Digital Twin can improve the speed and quality of decision-making in emergency response scenarios.
2. Provide guidance and context to other organizations interested in exploring Digital Twins for scenario response planning. The aim is to accelerate the adoption of this technology by sharing lessons learned, best practices, and pathways for evaluating project success.
3. Generate transition pathways for the developed technology and ideally create a ramp to commercial availability. This will involve considering both private industry needs and benefits of the technology, as well as governmental and regulatory interests in future emergencies, particularly with regards to regulation.

Project Objective

The objective of the revamping is to lift-and-shift an existing manufacturing cell to showcase the possibility of maintaining continuity in the face of unforeseen circumstances.

We will demonstrate the benefits of Digital Twin technology in formulating scenario response plans for manufacturing cells. The goal is to showcase the possibility of maintaining continuity in the face of unforeseen circumstances such as equipment failure, natural disasters, or supply chain disruptions.

Use Cases

The project aims to use digital twin technologies to accomplish two goals:

1. A descriptive digital twin to monitor the status of raw material and work-in-progress to prevent process shutdowns due to material shortages. This will correspond to the first use case: As a production planner, I need visibility into my production process status in order to anticipate shortages or excess WIP and avoid line slowdown.
2. A Virtual Commissioning Digital Twin to make programming changes to a robot control system to optimize thruput without interrupting production. This will correspond to the second use case: As a manufacturing engineer, I need to test the impact of robotic programming changes in a virtual environment in order to evaluate different scenarios and their impact.

Scope of Work

• Design and Installation of a Production Cell – The cell will follow a digital thread process from design to finished good to provide a robust base for testing and demonstrating digital twins.
• Creation of 2D Descriptive Process Digital Twin – Monitor the status of sensors, work-in-progress, buffer/raw material, and other parameters, using information from the manufacturing process to enhance performance.
• Creation of 3D Robotic Virtual Commissioning Digital Twin – Enable a programmer to make programming changes to a robot control system to optimize throughput of the robot without interrupting production.

Partnership Model

• Numorpho’s DTWM reference architecture will provide the orchestration layer to plan, define and manage the end-to-end lifecycle of the test bed.
• @mHUB – We plan to utilize mHUB resources and its extended ecosystem.
• Microsoft’s Azure Cloud/Desktop provisioning will be the basis for the data and process management using Dynamics 365 and Power platforms.
• PTC’s Infinity Loop is a closed loop Model Based Digital Thread Manufacturing process that ties in their tools to enable digital twinning, the management of physical assets and the creation of products.
• Oqton’s Manufacturing Operating System

Process Flow Diagram

• Current State (supplied by RFP)

Process Orchestration

Inbound Processes

Manufacturing Processes

Outbound Processes

SUMMARY

The CFDT represents a holistic approach to digital transformation that promotes seamless collaboration and orchestration across all stages of the manufacturing value chain. This not only enables organizations to respond more effectively to disruptions, but also facilitates the creation of new business models and revenue streams.

NITIN UCHIL Founder, CEO & Technical Evangelist
nitin.uchil@numorpho.com

REFERENCES

• Microsoft’s Federal Business Unit

  Microsoft’s Federal Business Unit is a specialized division within Microsoft that focuses on providing technology solutions and services to the U.S. federal government. The unit works closely with various government agencies, departments, and contractors to develop and deliver innovative technology solutions that meet the unique needs and requirements of the federal government.

  The Federal Business Unit offers a range of products and services, including cloud computing platforms, productivity tools, collaboration and communication tools, and cybersecurity solutions. These offerings are designed to help government agencies and departments improve their operations, enhance their security, and drive innovation through the power of technology.

  One of the key areas of focus for the Federal Business Unit is cloud computing. Microsoft Azure Government is a specialized version of the Azure cloud platform that is designed specifically for use by government agencies and their partners. This platform offers advanced security features, compliance certifications, and other capabilities that make it an ideal choice for federal government organizations.

  Overall, the Federal Business Unit is dedicated to helping federal government agencies and departments achieve their mission objectives by leveraging the latest technology solutions and services.

• Microsoft’s Defense and Intelligence Business Unit is a specialized division within Microsoft that focuses on providing technology solutions and services to the defense and intelligence communities. The unit works closely with government agencies, defense contractors, and other organizations in the defense and intelligence sector to develop and deploy innovative technology solutions that address the unique challenges and requirements of this industry. The Defense and Intelligence Business Unit offers a range of products and services, including cloud computing platforms, data analytics tools, collaboration and communication tools, and cybersecurity solutions. These offerings are designed to help defense and intelligence organizations improve their operations, enhance their security, and drive innovation through the power of technology.One of the key areas of focus for the Defense and Intelligence Business Unit is cloud computing. Microsoft Azure Government is a specialized version of the Azure cloud platform that is designed specifically for use by government agencies and their partners. This platform offers advanced security features, compliance certifications, and other capabilities that make it an ideal choice for defense and intelligence organizations.Overall, the Defense and Intelligence Business Unit is dedicated to helping defense and intelligence organizations achieve their mission objectives by leveraging the latest technology solutions and services.
• Microsoft’s Industry Cloud is focused on providing cloud-based solutions and services for specific industries, including manufacturing. Its Cloud for Manufacturing offering is designed to help manufacturers accelerate their digital transformation journey by providing a suite of tools and services that enable them to connect, analyze, and optimize their operations. Cloud for Manufacturing includes a range of pre-built solutions and templates, as well as a set of platform services that can be customized to meet specific business needs. The platform provides advanced analytics capabilities, including machine learning and artificial intelligence, that enable manufacturers to gain valuable insights into their operations, optimize performance, and reduce costs.Cloud for Manufacturing is built on Microsoft Azure, which is a highly secure and scalable cloud computing platform that enables manufacturers to run their applications and services in a flexible and cost-effective manner. The platform also supports integration with a wide range of enterprise systems and applications, making it easy for manufacturers to connect and share data across their organization.Overall, Cloud for Manufacturing is a comprehensive cloud-based solution that can help manufacturers improve their operations, reduce costs, and drive innovation through the power of digital transformation.
• Oqton’s Manufacturing Operating System (MOS) is a cloud-based platform that combines the power of artificial intelligence, machine learning, and advanced analytics to optimize manufacturing operations. The platform enables users to automate and optimize all aspects of the manufacturing process, from design and planning to execution and analysis. The MOS provides a centralized dashboard for managing all manufacturing operations, including production scheduling, resource allocation, quality control, and supply chain management. The platform uses advanced algorithms and analytics to optimize production workflows, reduce waste, and improve overall efficiency. It also includes a range of tools for 3D printing, CNC machining, and robotic automation, making it a highly flexible and scalable solution for modern manufacturing environments.
• PTC’s Infinity Loop is a comprehensive model-based digital thread manufacturing process that integrates various tools to enable digital twinning, asset management, and product creation. PTC offers a range of software solutions that play a crucial role in different aspects of the manufacturing process.

https://www.ptc.com/en/blogs/corporate/product-development-transformation

Here’s an elaboration on some of their key tools and acquisitions:

1. Onshape: Onshape is a cloud-based computer-aided design (CAD) software that allows teams to collaborate in real-time on 3D modeling and design. It facilitates the creation and management of digital product models, providing a foundation for the digital thread.
2. Windchill: Windchill is a product lifecycle management (PLM) software that enables organizations to manage and track product data throughout its lifecycle. It helps in managing product information, change management, and collaboration across cross-functional teams.
3. Creo: Creo is a parametric 3D CAD software that enables engineers to create and modify digital product designs. It provides a wide range of design tools and capabilities for creating complex product geometries.
4. ThingWorx: ThingWorx is an industrial IoT platform that enables organizations to connect and collect data from various devices, sensors, and equipment. It allows for real-time monitoring, data analysis, and remote asset management, supporting the digital twinning concept.
5. Vuforia: Vuforia is an augmented reality (AR) platform that enables the creation and deployment of AR experiences for industrial applications. It allows manufacturers to overlay digital information and instructions onto the physical world, facilitating tasks such as assembly, maintenance, and training.
6. Arena: Arena Solutions is a cloud-based product lifecycle management and quality management software provider that offers solutions for managing bills of materials (BOMs), change processes, and quality control.

PTC has also made acquisitions in the supply chain and service domains to further enhance their digital thread capabilities. These acquisitions include companies like Servigistics, which provides service lifecycle management solutions, and ThingWorx, which specializes in industrial IoT and connected products.

By integrating these tools and acquisitions, PTC’s Infinity Loop aims to establish a closed-loop digital thread that connects the design, manufacturing, and service aspects of a product’s lifecycle. This enables organizations to have a holistic view of their products, improve collaboration, optimize processes, and deliver better products and services to their customers.

• Siemens Mendix is a low-code platform for building and deploying custom business applications. The platform enables users to rapidly create and deploy applications without requiring extensive coding knowledge or experience. Mendix provides a visual development environment that allows users to drag and drop components to create applications. The platform includes a range of pre-built templates, components, and connectors that can be easily customized to meet specific business requirements. Mendix supports the full application lifecycle, from design and development to deployment and maintenance. The platform also includes a range of collaboration and governance tools, making it an ideal solution for enterprise-level application development.
• Siemens Mindsphere is a cloud-based platform for the Internet of Things (IoT) that enables users to collect, analyze, and visualize data from a wide range of connected devices and sensors. The platform provides a comprehensive set of tools and services for developing and deploying IoT applications, including data analytics, machine learning, and predictive maintenance. Mindsphere also includes a range of pre-built applications and solutions that can be easily customized to meet specific business requirements. The platform is highly secure and scalable and supports integration with a wide range of enterprise systems and applications. With Mindsphere, organizations can gain valuable insights into their operations, optimize performance, and drive innovation.