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Digital twins (DTs) offer the potential for improved understanding of current and future manufacturing processes. This can only be achieved by DTs consistently and accurately representing the real processes. However, the robustness and resilience of the DT itself remain an issue. Accordingly, this paper offers an approach to deal with uncertainty and disruptions, as the DT detects these effectively and self-adapts as needed to maintain representativeness. The paper proposes an intelligent agent-based architecture to improve the robustness (including accuracy of representativeness) and resilience (including timely update) of the DT. The approach is demonstrated on a case of cryogenic secondary manufacturing. [ABSTRACT FROM AUTHOR]

In manufacturing supply chains with labour-intensive operations and processes, individuals perform various types of manual tasks and quality checks. These operations and processes embrace engagement with various forms of paperwork, regulation obligations and external agreements between multiple stakeholders. Such manual activities can increase human error and near misses, which may ultimately lead to a lack of productivity and performance. In this paper, a multi-agent cyber-physical system (CPS) architecture with radio frequency identification (RFID) technology is presented to assist inter-layer interactions between different manufacturing phases on the shop floor and external interactions with other stakeholders within a supply chain. A dynamic simulation model in the AnyLogic software is developed to implement the CPS-RFID solution by using the agent-based technique. A case study from cryogenic warehousing in cell and gene therapy has been chosen to test the validity of the presented CPS-RFID architecture. The analyses of the simulation results show improvement in efficiency and productivity, in terms of resource time-in-system. [ABSTRACT FROM AUTHOR]

For complex manufacturing systems, the current hybrid Agent-Based Modelling and Discrete Event Simulation (ABM–DES) frameworks are limited to component and system levels of representation and present a degree of static complexity to study optimal resource planning. To address these limitations, a modular hybrid simulation framework for complex manufacturing system design is presented. A manufacturing system with highly regulated and manual handling processes, composed of multiple repeating modules, is considered. In this framework, the concept of modular hybrid ABM–DES technique is introduced to demonstrate a novel simulation method using a dynamic system of parallel multi-agent discrete events. In this context, to create a modular model, the stochastic finite dynamical system is extended to allow the description of discrete event states inside the agent for manufacturing repeating modules (meso level). Moreover, dynamic complexity regarding uncertain processing time and resources is considered. This framework guides the user step-by-step through the system design and modular hybrid model. A real case study in the cell and gene therapy industry is conducted to test the validity of the framework. The simulation results are compared against the data from the studied case; excellent agreement with 1.038% error margin is found in terms of the company performance. The optimal resource planning and the uncertainty of the processing time for manufacturing phases (exo level), in the presence of dynamic complexity is calculated. [ABSTRACT FROM AUTHOR]