Autonomous, Context-Aware, Adaptive Digital TwinsState of The Art and Roadmap
Autonomous, Context-Aware, Adaptive Digital TwinsState of The Art and Roadmap
Computers in Industry
journal homepage: www.elsevier.com/locate/compind
a r t i c l e i n f o a b s t r a c t
Article history: Digital Twins are an important concept in the comprehensive digital representation of manufacturing
Received 20 January 2021 assets, products, and other resources, comprising their design and configuration, state, and behaviour.
Received in revised form 21 June 2021 Digital Twins provide information about and services based on their physical counterpart’s current condi-
Accepted 28 June 2021
tion, history and predicted future. They are the building blocks of a vision of future Digital Factories where
Available online 13 October 2021
stakeholders collaborate via the information Digital Twins provide about physical assets in the factory
and throughout the product lifecycle. Digital Twins may also contribute to more flexible and resilient Dig-
Keywords:
ital Factories. To achieve this, Digital Twins will need to evolve from today’s expert-centric tools towards
Digital Twins
Digital Factories
active entities which extend the capabilities of their physical counterparts. Required features include
Context-awareness sensing and processing their environment and situation, pro-actively communicating with each other,
Autonomy taking decisions towards their own or cooperative goals, and adapting themselves and their physical
Adaptivity counterparts to achieve those goals. Future Digital Twins will need to be context-aware, autonomous,
and adaptive. This paper aims to establish a roadmap for this evolution. It sets the scene by proposing a
working definition of Digital Twins and examines the state-of-the-art in the three topics in their relation
to DTs. It then elaborates potentials for each topic mapped against the working definition, to finally iden-
tify research gaps allowing for the definition of a roadmap towards the full realisation of autonomous,
context-aware, adaptive Digital Twins as building blocks of tomorrow’s Digital Factories.
© 2021 Elsevier B.V. All rights reserved.
Contents
1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. A working definition of Digital Twins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1. System state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2. System design and configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3. System behaviour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. State-of-the-art . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1. Context-Awareness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2. Autonomy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3. Adaptivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4. Research and development gaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5. Conclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Acknowledgements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
∗ Corresponding author.
E-mail addresses: [email protected] (K. Hribernik), [email protected] (G. Cabri), [email protected] (F. Mandreoli), [email protected]
(G. Mentzas).
https://doi.org/10.1016/j.compind.2021.103508
0166-3615/© 2021 Elsevier B.V. All rights reserved.
K. Hribernik, G. Cabri, F. Mandreoli et al. Computers in Industry 133 (2021) 103508
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K. Hribernik, G. Cabri, F. Mandreoli et al. Computers in Industry 133 (2021) 103508
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K. Hribernik, G. Cabri, F. Mandreoli et al. Computers in Industry 133 (2021) 103508
2.3. System behaviour between external and internal context (Alexopoulos et al., 2016).
The former relates to places, people and their roles, and things.
DTs include integrated “ultra-realistic, high-fidelity” (Glaessgen The latter describes goals, tasks, work contexts, business processes,
and Stargel, 2012; Sha to et al., 2012) models describing their phys- communication, and even emotional and physical states.
ical counterpart’s behaviour (Rosen et al., 2015; Glaessgen and Context modelling is used to organise context information,
Stargel, 2012; Reifsnider and Majumdar, 2013; Lee et al., 2013). allowing, for example, to define context types, relationships, and
To illustrate, predicting the remaining useful life of an aircraft dependencies between context information, and to control qual-
requires detailed modelling of its response to aerodynamic, high- ity and consistency. Context models also facilitate reasoning on
frequency sonic and dynamic loads, and thermal fluxes (Tuegel and context information. Different approaches can be taken to context
Ingraffea, 2011). In addition, simulation needs to model e.g., the modelling, including graphical and object-oriented, logic-based
history of the structure’s response to forces to analyse potential and semantic modelling (Lee and Martinez Lastra, 2013).
damage. This necessitates integrating many models: e.g. multi- Different technologies can be exploited to generate and com-
physics and damage modelling, models for dealing with aleatory municate context information in manufacturing environments.
and epistemic uncertainty derived from interval theory, and high- Context information describing environmental parameters can
resolution structural analysis (Tuegel and Ingraffea, 2011). Besides be sourced, for example, from sensors and embedded systems
multi-physics and numerical modelling (e.g. 3D modelling) and (Alexopoulos et al., 2016; Azouz and Pierreval, 2019), RFID
simulators (e.g. finite element methods), data driven analytics is (Alexopoulos et al., 2016), BLE (Bisio et al., 2018), NFC (Alexopoulos
becoming increasingly relevant (Tao et al., 2019a). This assumes et al., 2016), IoT (Alexopoulos et al., 2016; Bisio et al., 2018; Lee et al.,
that since data is a manifestation of both known and unknown 2016) and CPS (Alexopoulos et al., 2016). Context can also be more
physical factors, a data-driven model can account for a better vir- broadly understood to include not only the environment of sensors
tual model in a non-parametric setting and to anticipate events. and embedded devices, but also the users and their preferences
Various machine learning and artificial intelligence techniques are (Bisio et al., 2018). In manufacturing, context-aware applications
useful for the development of data-driven models, while a recent may also utilise information e.g. about the planning and execution
effort tries to consistently integrate the various approaches in the of manufacturing processes, which can be provided by IT systems
overall vision of DTs (Rasheed et al., 2019). such as manufacturing execution (MES) or enterprise resource
planning (ERP) systems (Alexopoulos et al., 2016). This may also
include a history of events related to products and resources (Azouz
3. State-of-the-art
and Pierreval, 2019). Since the system state component of a DT
reflects the status of a physical object as monitored e.g., by sensors,
Currently, no literature specifically addresses context-
IoT devices and other sources, DTs can act as providers of context
awareness, autonomy and adaptivity together in relation to
information to other DTs.
DTs. Literature specifically addressing the application of the
Context-awareness can contribute to the “smartness” of facto-
individual properties to DTs is also lacking. This paper conse-
ries and manufacturing environments (Radziwon et al., 2014). By
quently focuses on examining the three properties to identify their
bridging the gap between the virtual and physical worlds using IoT,
potentials for DTs. These three properties are often discussed in
objects can be made recognizable and smart, and context-related
conjunction with one another, as illustrated in Fig. 2. For example,
decisions can be supported in a smart factory environment (Bisio
context-awareness and adaptivity intersect where a system’s
et al., 2018). Examples of application areas in smart manufacturing
behaviour is modified based on information about its logical,
include energy management, failure management, manufacturing
physical, and/or external context. Likewise, autonomous systems
cycle time optimisation, shop-floor management, and manufac-
or entities may use context-awareness to take decisions based on
turing system reconfiguration. Context-aware energy management
information about their environment or situation. Autonomous
enables users to monitor and control their energy consumption in
entities can show adaptive behaviour when their decisions lead
a smart way, so they can control their utilities and equipment and
to the modification of the entity’s behaviour. This paper focuses
adapt their behaviour in order to avoid energy waste (Lee et al.,
on applying all three properties to DTs: DTs which are aware
2016). In mass production with high volumes and low profit mar-
of their own context, capable of autonomous decision-making
gins, context awareness can help optimize manufacturing cycle
and adapting themselves, their physical counterparts, and by
times. It has been shown to contribute to managing high product
extension, the systems within which they operate.
variety and batch size variation when handling many parts, e.g. in
white goods manufacturing (Alexopoulos et al., 2016). In failure
3.1. Context-Awareness management, context-awareness allows interventions to be more
effective because they can be focused on what happened and in
Context-awareness is the capability of customizing the which environment (Wieland et al., 2010). Shop-floor management
behaviour of a system or of a component depending on the con- can be improved by context-awareness by using sensors to expose
text in which it executes to make it more effective or relevant to processes in a clearer way, providing the right information, to the
the situation in which it is being used (Lucke et al., 2008). Context is right people, at the right time (Alexopoulos et al., 2016), support-
any information that can be used to characterise the situation of an ing worker’s decisions by providing useful information in the right
entity (Alexopoulos et al., 2016), such as a person, place, or physical context (Lee and Martinez Lastra, 2013).
or computational object (Lee and Martinez Lastra, 2013). A context- Making DTs context-aware will contribute to a more holistic
aware system can access and process information which describes representation of their physical counterparts including their environ-
context. What constitutes context information can been classified ment and execution context (Borangiu et al., 2019), which is helpful
in different ways. A prominent classification distinguishes pri- for e.g. HRC applications, where a robot’s position needs to be con-
mary (time, identity, location and activity) and secondary context sidered in relation to humans. Context-awareness in DT literature
which can be derived from the primary ones (Alexopoulos et al., is found mainly in CPS-related research relating to the system state
2016). These basic classes are not always appropriate for industrial component. An early approach to context-aware DTs in CPS includes
applications, which can benefit from a more specific classification context information in the representation of the system state of a
such as user, environment and production contexts (Rosenberger production plant, via a separate context-aware application (Park
and Gerhard, 2018). Another helpful classification distinguishes et al., 2020). In this case, the DT itself is not fully context aware.
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K. Hribernik, G. Cabri, F. Mandreoli et al. Computers in Industry 133 (2021) 103508
DTs can contribute to processing context information generated by 2009). This makes autonomy an interesting approach for systems
CPS, since CPS generally focus on the physical layer of embed- about which little is known in advance.
ded systems (Leng et al., 2019). They have also been proposed to Smaller organisational units need to receive and process infor-
improve the identification of relevant contexts in smart manufactur- mation about their environment to take their own decisions
ing systems (Preuveneers et al., 2018). DTs should also act as context (Scholz-Reiter et al., 2021; Scholz-Reiter, 2004). Realising auton-
information sources for other networked DTs, allowing them to pro- omy thus requires linking the physical to the virtual world hosting
cess information about their environment, an important ingredient IT capable of autonomous decision-making. Technologies such as
for distributed, autonomous decision-making. DTs should also be smart or intelligent processes, IoT, CPS, and indeed DTs, support
able to access appropriate data sources based on context changes. this link (Maes, 1993).
A physical counterpart’s context may require changes to its Autonomous decision-making is often modelled on biological
configuration, affecting the DT’s system design component. For systems, for example, how humans or animals perform control
example, a machine tool might need to be configured to carry out tasks, recognise patterns and make decisions (Passino, 1995).
a specific task (changing moulds or tools). The DT should be able to Examples of these methods range from simple due date (Windt
understand the context to reflect this in its design models and configu- et al., 2010), queue-length estimation and rule-based approaches
ration appropriately. For example, a DT architecture for cloud-based (Gebhardt et al., 2011) through fuzzy control, fuzzy supervisory
cyber-physical systems supports context-aware self-reconfiguration control, fuzzy learning control, knowledge-based control, neural
of manufacturing systems to increase the resilience of manufactur- networks and genetic algorithms (Passino, 1995). Many methods
ing systems, applying fuzzy rules and Bayes networks to the system of decision-making in autonomous systems rely on the interac-
context (Alam and El Saddik, 2017). This contributes to production tion, cooperation or competition of individual units (Hülsmann and
system adaptivity. Windt, 2007). The dynamics of such an interaction “can lead to emer-
To realise context-awareness, DTs must incorporate context gent structure or emergent functionality” (Maes, 1993). Emergent
models into their system behaviour component, including models behaviour may be Predicted Desirable (PD), Unpredicted Desirable
of system tasks, processes, objectives, and operations. They must (UD), Predicted Undesirable (PU), or Unpredicted Undesirable (UU)
access knowledge about their context, or include models reflect- (Grieves and Vickers, 2016). Desirable behaviour is, for example, an
ing their operational context. Graph-based models can represent increase in the robustness of the overall system due to distributed
components involved in smart manufacturing processes along with and flexible handling of dynamics and complexity (Hülsmann and
their relations, constraints and paths (Zheng and Sivabalan, 2020). Windt, 2007). DTs can help manage emergent behaviour, guarantee
This allows the DT to apply context-aware cognition to its tasks. obtaining PD, eliminate PU, and decrease UU behaviour (Grieves
A context model which includes the states of all objects, e.g., and Vickers, 2016). Methods supporting this kind of decision-
machines, tools, production processes, material, in a production making include swarm intelligence approaches (Mullen et al., 2009)
facility has been integrated into DTs which constitute a “social fac- such as ant algorithms (Gebhardt et al., 2011) and bee foraging algo-
tory”, that is a smart factory which focusses on the interactions rithms (Windt et al., 2010), Distributed Logistics Routing Protocol
between people and the production environment (Kassner et al., (DLRP) (Scholz-Reiter et al., 2008), Link-state internet routing pro-
2017). tocol (LSIRP), asynchronous teams (Talukdar et al., 1998), holonic
manufacturing algorithms (Windt et al., 2010), or auction algo-
rithms for decentralized parallel machine scheduling (Attanasio
3.2. Autonomy et al., 2006).
Autonomous systems not only need to be able to react to
A dictionary definition of autonomy is “freedom from external changes in their environment, but also to act proactively with
control or influence; independence” (autonomy, 2021). More specifi- respect to their own purposes. A proactive and anticipatory sys-
cally, it is “the ability to act with some measure of independence, and to tem contains “a predictive model of itself and/or its environment,
assume responsibility for one’s own resources and behaviour” (Steiner, which allows it to change state at an instant in accord with the
2008). From a technical perspective, “[a]gent X is autonomous from model’s predictions pertaining to a later instant” (Nadin, 2017; Louie,
agent Y to the degree that X pursues its goals without input from Y” 2010). Proactive computing is currently understood as an evolution
(Müller, 2012). More autonomy implies less control (Müller, 2012), away from interactive computing, towards human-(un)supervised
qualifying “freedom from external control” above. Entities may have pervasive computing scenarios (Tennenhouse, 2000). Proactivity
varying degrees of autonomy and be subject to inverse degrees of extends reactivity, referred to in literature as sense-and-response
external control. (Elwany and Gebraeel, 2008) or detect-and-act (Tao et al., 2014) – to
Autonomy can help handle disturbances, changing market a new model of situational awareness with four phases: Detect, Pre-
demands or other unforeseen events by shifting decision-making dict, Decide, Act (Engel et al., 2012). “Detect” deals with monitoring
to smaller organizational units, which can contribute to increasing and detecting current indicators. “Predict” uses those indicators to
the system’s flexibility and adaptability to changes or disturbances forecast when the system will leave an admissible state if noth-
(Hülsmann and Grapp, 2005; Antsaklis et al., 2021). Resources may ing changes. “Decide” takes real-time decisions about how best
be autonomously reconfigured, restructured or rescheduled to con- to eliminate or mitigate the problem and remain in an admissible
tinue production with minimal downtime (Park and Tran, 2011). state. The “Act” deals with the actual implementation of that action.
Autonomy also helps tackle very unstructured or complex envi- Proactive event-driven architectures combine advanced event pro-
ronments which cannot be appropriately anticipated (Pachter and cessing with dynamic forecasting capabilities leveraged towards
Chandler, 1998) since shifting decision-making to smaller units online optimisation and decision-making (Lindberg, 1990). The
breaks the total complexity of the system down to partial complex- decisions are made in real time and require swift and immediate
ity (Hülsmann and Grapp, 2005). Decentralizing decision-making processing of big data, that is, extremely large amounts of noisy
allows for a problem decomposition which reduces computational data flooding in from various locations, as well as historical data
effort (Schuldt et al., 2011). In very complex systems, linear plan- (Bousdekis et al., 2015, 2017; Bousdekis et al., 2019; Petersen et al.,
ning and scheduling can be difficult, and optimization can take 2016).
considerable effort (Gebhardt et al., 2011). Autonomous systems DT characteristics lend themselves to implementing autonomy
alleviate these difficulties by reducing the need for a-priori plan- and are already considered core enablers of autonomous systems
ning and optimisation by local decision-making (Hülsmann et al., (Cronrath et al., 2019; Rassolkin et al., 2019). However, current lit-
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K. Hribernik, G. Cabri, F. Mandreoli et al. Computers in Industry 133 (2021) 103508
erature describes DTs as expert-centric tools without autonomous and control of a manufacturing system are too fast, frequent,
capabilities (Hartmann et al., 2018), and their evolution towards complex, or unpredictable for human intervention at run-time,
active components which extend the characteristics of their phys- adaptivity based on MAS (multi-agent systems) can help man-
ical counterparts is not yet complete (Saracco, 2019; Dambrot, age industrial control systems with the required speed (Sanderson
2021). The system state component links the physical and virtual et al., 2015). Small-scale adaptivity realised by context-aware dis-
worlds, which is a basic requirement for realising autonomous enti- tributed, autonomous CPS which monitor themselves can also
ties. A full control loop is required for the DT to autonomously help ensure and optimize production quality. By storing informa-
control its physical counterpart. Here, principles of autonomous tion about quality and process execution in each product’s own
control, both reactively and proactively, may be applied. Agent, CPS-enabled memory, deviations can be detected directly in the
holon or CPS principles may inspire the implementation of DT production line and corrected accordingly (Bergweiler, 2016).
autonomy. First considerations towards the convergence of DT and In smart manufacturing, the detection of sensor or actuator out-
CPS, formalised in the RAMI 4.0 Asset Administration Shell, exem- liers that deviate from the expected parameters as modelled may
plify this (Wagner et al., 2017). either indicate a fault in the sensor/actuator or a change in the
With regards to system design, based on simulations and analy- process. Once a decision is made between these two options, mod-
sis in conjunction with real-time and historical data about physical els may need to be adapted to reflect the change. A rapid (e.g.
assets, DTs could autonomously take decisions about the product discarding historical data before the change) or gradual (e.g. expo-
design and configuration and influence future product design itera- nential forgetting) approach can be used to facilitate self-adaptive
tions (Lützenberger et al., 2016; Klein et al., 2019]. The configuration modelling to address this problem (He and Wang, 2018). Adaptiv-
of the physical counterpart can also be influenced by the DT in this ity can also contribute to dynamically organising supply chains in
way (Wuest et al., 2013). In predictive maintenance, the DT may multi-organisational collaborations and thus optimising produc-
take autonomous decisions with regards to maintenance, affecting tion (Radziwon et al., 2014), or dynamically on multiple levels for
the physical configuration of the asset (Hribernik et al., 2018). production logistics synchronisation, using Cloud Manufacturing
The advanced simulation and analytical capabilities offered in combination with IoT to dynamically synchronise logistics plans
by DTs’ system behaviour component, fed with high-resolution and collaborations (Qu et al., 2016).
real-time system state data and extended by context-awareness Changing systems to meet the needs of workers is another sig-
allows more accurate predictive capabilities, which can improve nificant area of application, and is fundamental to efficient and
autonomous decision-making in industrial scenarios (Rosen et al., effective smart manufacturing systems (Peruzzini and Pellicciari,
2015). Furthermore, context-awareness could allow DTs to 2017). For example, aging workers may have different profiles of
autonomously select, integrate, and execute appropriate physical, physical and cognitive limitations, restricting their ability to work
simulation, and analytical models. For example, different physical at standardised workplaces. A methodology has been proposed to
models are required for a spacecraft travelling in a planet’s atmo- self-adapt manufacturing systems to their needs (Peruzzini and
sphere or in space (orbital mechanics models). Pellicciari, 2017). User interfaces and information provision in man-
ufacturing can also be adapted to workers’ needs. Humans tend to
3.3. Adaptivity behave in nondeterministic, flexible ways and adapt themselves to
changing environments (Joo and Shin, 2019). This means that HMI
Adaptivity is the capability to modify a system or component’s (human–machine interaction) should be designed to provide them
behaviour depending on unpredicted situations to achieve one or with the appropriate level of information depending on different
more goals. It describes how well a machine or group of machines system states (de Visser and Parasuraman, 2011; Inagaki, 2003).
can adapt to change, which can be measured by comparing the An example is preventing mode confusion, where humans work
weighted flexibilities of two situations occurring at different points with mental models about a process that conflicts with those of
in time (Mandelbaum, 1978). Adaptivity is an objective of Industrie involved machines, or receive confusing feedback from their user
4.0 and Cloud Manufacturing (Qu et al., 2016) and a core charac- interfaces (Joo and Shin, 2019).
teristic of smart factories, defined as a “manufacturing solution that DT adaptivity may refer to the capability of the digital repre-
provides such flexible and adaptive production processes that will solve sentation, the physical counterpart, or both, to adapt. Regarding
problems arising on a production facility with dynamic and rapidly system state, literature highlights DTs’ potential to optimise or mod-
changing boundary conditions in a world of increasing complexity” ify their counterparts’ control parameters based on awareness of their
(Radziwon et al., 2014). current operation conditions (Tao et al., 2019a). For example, DTs
Adaptivity involves monitoring the state and/or environment using adaptive algorithms can change production system control con-
of the system or component whose behaviour is to be changed. figurations ensuring safe operations when faults occur (He et al.,
Relevant information can be sourced in real-time, e.g. from IoT, 2019). Context changes can trigger the DT to modify data sources
Industrial IoT systems or CPS (Qu et al., 2016; Bergweiler, 2016). for an optimal reflection of the physical asset. For example, changes
Suitable decision-making mechanisms are required to enact adap- to the stakeholder network of a Digital Factory may require the DT
tivity once a system state is detected that requires modification. to access new enterprise systems or disconnect no longer relevant
Examples include case-based reasoning (Peruzzini and Pellicciari, ones. The DT should thus autonomously recognise the need, discover
2017) and decentral decision-making based on autonomous enti- appropriate data sources, and (disc)connect those sources. Another
ties as described above (Gonçalves and Peschl, 2018; Sanderson interesting example is represented by robotic work cells. As the
et al., 2015). tool of iterative refinement is calibration, its effective and system-
Adaptivity has been applied to different manufacturing prob- atic execution has to be ensured (Erdős et al., 2020). Since data can
lems. For example, it can help manage increasing complexity and be collected continuously from the real work cell, relevant infor-
unpredictability. By monitoring and identifying machine status in mation can be stored historically. When the DT model parameters
real time, maintenance can be appropriately triggered and produc- are out of the feasible tolerance region surrounding the real mea-
tion rescheduled via dynamic scheduling mechanisms (Mourtzis surements on the physical system, they need to be adjusted. The
et al., 2014). Decentralized, autonomous approaches have been DT should thus autonomously recognize such a divergent situation
shown to enable the dynamic reconfiguration of manufacturing and automatically recalculate the parameter values.
systems, increasing flexibility, adaptability to change, and fault Relating to system design, DTs can be considered adaptive mod-
tolerance (Gonçalves and Peschl, 2018). Where decision-making els of complex physical systems (Rasheed et al., 2019). Context-aware
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K. Hribernik, G. Cabri, F. Mandreoli et al. Computers in Industry 133 (2021) 103508
changes to the physical counterpart’s configuration and conse- Data Space reference architecture (Otto et al. (2018)), or Indus-
quently its DT may be required, requiring the DT to select, modify trial Ontologies Foundry (Kulvatunyou et al., 2018) are promising
and configure models appropriately in accordance with the situa- avenues of investigation. Underlying these interoperability issues
tion they represent whenever changes occur. Modifications can be is the need for work on standards and protocols for DT informa-
human-supervised or automatic. The changes can concern different tion exchange. The breadth of information, model and technology
aspects of the production cycle, e.g. products, services, stakehold- heterogeneity and the use of DTs in different sectors makes stan-
ers, and the general context. Here, a technical barrier is adapting dardization for DT interoperability extremely challenging.
models to avoid discrepancies over time, e.g. due to degradation. The next line deals with modelling. The model-based nature
Model updating schemes have been put forward to facilitate adap- of DTs means that context models need to be incorporated to use
tive models in DTs (Lu et al., 2019; Wang et al., 2019). context in combination with other models on the level of system
An adaptive physics-based performance model has been used in behaviour. This is a significant step towards enabling autonomous,
a DT of aero-engines to generate fault signatures that can be com- adaptive DTs. DTs capable of understanding and acting upon con-
pared with measured flight data to assess the engine conditions text will be able to identify, connect to and collaborate with other
(Zaccaria et al., 2018). DTs can contribute to the dynamic adapt- DTs sharing their context. Several DTs in a common manufacturing
ability of manufacturing execution systems, performing real-time context within a production line could join together to form an
optimization of products and production processes (Zhang et al., autonomous, adaptive virtual production line. Research towards
2017). Machine learning has been put forward as a way for DTs understanding how individual DTs may connect and collaborate
to adjust system behaviour with minimal need for supervision is required. Agents, holons and CPS are furthermore good exam-
(Madni et al., 2019). Context may influence the parameters of or ples of how autonomous decision-making can be modelled and
necessitate new physical, simulation and analytical models. On one implemented based on digital representations of physical entities
level, adaptation influences the physical counterpart’s configura- (Giret and Botti, 2004). Their relation to DTs has however not yet
tion, depending on the goals defined by the models. The models been studied deeply (Rosen et al., 2015); these paradigms can also
do not change, but trigger adaptation. On a higher level, context contribute to understanding general issues such as the required
change may require model modification: models representing the granularity of mapping of DTs to physical counterparts and managing
physical counterpart should be modified or replaced. Self-ware emergent system behaviour. Due to the complexity of the system of
models can be used which understand when and how to modify systems created by networking DTs, promoting PD and UD whilst
themselves (Schaumeier et al., 2012). mitigating undesirable behaviour will be challenging. Again, inves-
Adaptive interaction with DTs is also considered in literature, with tigating and adapting methods successfully applied in the fields of MAS
adaptive user interfaces proposed which learn the preferences and and HMS can contribute to solving this problem. Concepts such as
priorities of their users in different contexts and change accordingly resource, operational and product holons (Van Brussel, 2014; Leitão
(Madni et al., 2019, 1982). et al., 2003) and product agents (Främling et al., 2003) need to be
looked at in this light. Agent-based and Holonic Manufacturing Sys-
tems (HMS) have successfully shown how digital representations
4. Research and development gaps of physical entities can autonomously cooperate in a manufactur-
ing context towards common goals (Giret and Botti, 2004; Botti
This section identifies the research and development gaps to be and Giret, 2008; Wang and Haghighi, 2016) and can help under-
bridged to realise the potentials of DTs summarised in Table 1. stand how systems of networked DTs may be organised e.g. as agent
Fig. 3 below shows a roadmap of identified research challenges heterarchies/holarchies.
towards context-aware, autonomous, adaptive DTs. It is read from An issue regarding adaptivity is the definition of mechanisms
top to bottom, left to right. It shows one line for each issue and a for the translation of business goals into actionable plans that the
separate one for general issues. Research gaps are shown at the physical counterpart can carry out and can adapt in response to
intersection of these lines with those of the identified research unexpected situations. Methods and corresponding models are
topics and are as described in the following. required to achieve this translation, to realise the potentials of DTs
The first line deals with interoperability. To enable the poten- to act autonomously and adaptively within the context of higher-
tials of context-aware DTs, context information must be integrated level business goals. A further open issue is modelling interaction
into the system state component. A general issue here is matu- between networked DTs for cooperation and collaboration. Agent
ration research towards its harmonization with the IoT paradigm. interactions are complex to manage, so simpler models might be
The role of DTs in IoT needs to be better understood, as well as more appropriate for DTs. DTs represent physical systems which
which IoT protocols are appropriate for DTs. This is a prerequisite may change over time. The models used to represent them need to
e.g. for including third party data sources into DTs. Further matu- reflect these changes. Appropriate evolving, dynamic and traceable
ration of OPC-UA as a core protocol of Industry 4.0 may contribute models are required. Research in this field exists but more work is
to solving this issue (Jaekel et al., 2020). The establishment of DFs necessary (Lu et al., 2019). Another general issue is that reference
built on networked DTs will require a comprehensive approach to models for DTs are lacking and a comprehensive framework is
inter- and intra-factory, supply chain and lifecycle-wide interoper- required to facilitate full-stack solutions and avoid fragmentation.
ability. Approaches in the intelligent CPS field to monitor physical A final general research gap regarding modelling relates to the
processes, create a virtual copy of the physical world and make abovementioned standards and protocols and reference models.
decentralized decisions (Lu, 2017) can be exploited for this pur- The work towards full integration of the DT concept with RAMI 4.0
pose. However, such approaches need to be revisited and extended wrt. AAS and its convergence with CPS must progress to reinforce
to be useful for DTs interoperability. Indeed, whilst the CPS con- its potential in smart manufacturing and Digital Factories.
cept focusses more on sensors and actuators and the integration The third line of research deals with DT human interaction. At
and collaboration of computing, communication and control, DTs the intersection with context-awareness, research is also required
emphasise models and data (Tao et al., 2019b), and go beyond as how to appropriately represent humans in context models used
CPS in their incorporation of the system behaviour element, with by DTs. Borders between DT and human autonomy must be investi-
simulation and prediction outside of the scope of the core CPS gated to ensure DTs have as much autonomy as possible without
concept. Therefore, combining DTs with semantic interoperability sacrificing human agency. This involves investigating workplace
approaches such as mediation (Shani et al., 2017), the Industrial safety, psychological factors of workers’ motivation, and the lim-
7
K. Hribernik, G. Cabri, F. Mandreoli et al. Computers in Industry 133 (2021) 103508
Table 1
Identified Potentials.
Context-Awareness • Identify relevant contexts • Context-aware configuration of • Integrate rich context models
• Process context information physical counterparts • Include physical, logical, and external
• Incorporate context information • Understand context and reflect it in context models
• Provide context information design models • Include models of tasks, objectives, and
• Context-aware data sources selection • Support design and configuration operations
• Include third party data sources adaptability
Autonomy • Context support for autonomous control • Feedback loop to design • Advanced, multi-model simulations in
• Proactive/reactive autonomous control • Feedback loop to configuration autonomous decision-making
• Autonomous networked entities • Feedback loop to maintenance • Context-aware, autonomous selection,
integration, and execution of physical,
simulation and analytical models
Adaptivity • Context-aware data source adaptation • Adaptive models of complex systems • Real-time system adjustment and
• Control parameter adaptivity • Design and configuration model optimisation
• Control configuration adaptivity adaptivity • Context-aware model adaptivity
• Context-aware behaviour model
adaptivity
• Self-aware, self-modifying models
itations of AI decision-making, etc. To effectively interact with starting point to address these issues. Specifically, solutions at the
humans in production, DTs need to be able to understand and pre- interface level represent the manufacturing space through Virtual
dict the behaviour of humans working alongside them in different and Augmented Reality based on multitouch and voice control
roles. Touching on adaptivity, Human-to-DT Interaction Models are (Gorecky et al., 2014). More visionary concepts discuss cognitive
required which consider different humans’ profiles and how and intelligent assistants using voice or even brain wave interfaces
by what medium interaction is appropriate. CPS too aim to include (Schirner et al., 2013). With respect to the control strategy, dis-
humans in the control loop of autonomous systems (Fantini et al., tributed manufacturing scheduling control paradigms have been
2016) and the solutions proposed in this field represents a good proposed which integrate the human decision-maker’s preferences
8
K. Hribernik, G. Cabri, F. Mandreoli et al. Computers in Industry 133 (2021) 103508
into the control process (Gaham et al., 2015). Finally, DT models, Acknowledgements
simulations and predictions need to be explainable and, in some
cases, certified for widespread industrial adoption, especially in This work is partly funded by the European Commission project
safety and security-critical human-machine interaction applica- H2020 UPTIME “Unified Predictive Maintenance System” (768634),
tions. the European Commission Marie Skłodowska-Curie Research and
The final research line deals with issues of data process- Innovation Staff Exchange (MSCA RISE) project FIRST “vF Interop-
ing for real-time, proactive decision-making. DTs will need eration suppoRting buSiness innovation” (734599), and the H2020
to acquire context information in real-time to enable real-time project DIH4CPS “Fostering DIHs for Embedding Interoperability in
decision-making and self-aware, self-modifying models capable. Cyber-Physical Systems of European SMEs” (872548).
Developments e.g. in ultra-low latency 5 G context-aware appli-
cations may inform these developments (Nunna et al., 2015).
Real-time, proactive decision-making itself requires methods for
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E., 2010. Using context-aware workflows for failure management in a smart in proceedings of international and national conferences. Moreover, she is associate
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Technol. International Journal of Knowledge-Based and Intelligent Engineering Systems (IOS
Windt, K., Becker, T., Jeken, O., Gelessus, A., 2010. A classification pattern for Press). She participated in many national and international projects and she is cur-
autonomous control methods in logistics. Logist. Res. 2, 109–120, http://dx.doi. rently one of the PI of the Marie-Curie RISE Project FIRST focused on Digital and Smart
org/10.1007/s12159-010-0030-9. factories. She served as PC member of many international conferences and sympo-
Wuest, T., Hribernik, K., Thoben, K.-D., 2013. Digital Representations of Intelligent siums and she is one of the organizers of the CAiSE workshop K̈ET4DF: Key Enabling
Products: Product Avatar 2.0. Springer, Berlin Heidelberg, pp. 675–684, http:// Technologies for Digital Factories¨. She was referee for European Research Coun-
dx.doi.org/10.1007/978-3-642-30817-8 66. cil (ERC) Starting Grant funding calls, Italian Ministry of University and Research
Zaccaria, V., Stenfelt, M., Aslanidou, I., Kyprianidis, K.G., 2018. Fleet monitoring and (MIUR) FIRB and SIR funding calls,France-South America STIC AmSud Program, and
diagnostics framework based on digital twin of aero-engines. Proc. ASME Turbo Austria FWF Program.
Expo, American Society of Mechanical Engineers (ASME), http://dx.doi.org/10.
1115/GT2018-76414. Gregoris Mentzas is full Professor of Management Infor-
Zhang, H., Liu, Q., Chen, X., Zhang, D., Leng, J., 2017. A Digital Twin-based approach mation Systems, School of Electrical and Computer
for designing and multi-objective optimization of hollow glass production line. Engineering, National Technical University of Athens
IEEE Access 5, 26901–26911, http://dx.doi.org/10.1109/ACCESS.2017.2766453. (NTUA) and Founder and Director of the Information Man-
Zhang, J., Zhao, C., Ni, B., Xu, M., Yang, X., 2019. Variational Few-Shot Learning. agement Unit (IMU) at the Institute of Communication and
Zheng, P., Sivabalan, A.S., 2020. A generic tri-model-based approach for product- Computer Systems (ICCS). His main research focus is on AI-
level digital twin development in a smart manufacturing environment. Robot. enabled decision making: augmenting human intelligence
Comput. Manuf. 64, 101958, http://dx.doi.org/10.1016/j.rcim.2020.101958. with data-driven approaches and using Artificial Intelli-
gence to elevate human decision-making competence. He
Karl A. Hribernik studied Computer Science at the Uni- has published 4 books and more than 300 papers in inter-
versity of Bremen. He worked as a software developer national peer-reviewed journals and conferences, has 5
at Productec Ingenieurgesellschaft mbH on both research best papers awards, sits on the editorial board of five inter-
and commercial e-logistics and e-commerce projects from national journals and has served as (co-)Chair or Program
1997 to 2002. He joined BIBA – Bremer Institut für Committee Member in more than 55 international conferences. He has led or con-
Produktion und Logistik GmbH as a research scientist tributed in more than 50 European research and development projects. Research
in 2002. He has been the head of the department of carried out by his group has led to the establishment of three internet technology
Intelligent ICT for Co-operative Production at BIBA since companies. His experience includes twelve years of management consulting in cor-
2013 and manages BIBA’s iotfablab. His research interests porate strategy and information systems strategy. He holds a Diploma Degree in
are focussed on product-centric information manage- Engineering (1984) and a Ph.D. in Operations Research and Information Systems
ment and closed-loop product lifecycle management, and (1988) both from NTUA.
include the investigation of the Internet of Things and
Industrie 4.0 in the product lifecycle; semantic models,
interoperability and search; item-level digital product representations and digital
twins; data analysis, AI and machine learning and knowledge-based engineering. He
has contributed to more than 100 papers in national and international proceedings
and has received multiple best paper awards.
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