Enhancing predictive maintenance in lean manufacturing for continuous process improvement using digital twin technology
Bibliographic record
Abstract
The latest advancement in digital technologies has greatly revolutionized modern manufacturing processes, particularly through the adoption of Lean Manufacturing initiatives aimed at minimizing wastage and enhancing operational efficiency. Predictive Maintenance (PM) being one of the primary drivers of transformation in lean manufacturing by reducing equipment downtime and optimizing asset performance. The lack of failure data is one of the biggest obstacles to PM deployment because traditional maintenance methods are used to maintain equipment after they break down. In order to address the issue of data scarcity, this study investigates the use of Digital Twin (DT) technology, which creates a virtual duplicate of the physical item and enables real-time monitoring utilizing sensors and Internet of Things devices for predictive analysis. IoT and data analytics are well complemented by digital twin technology, giving the manufacturer access to real-time information about the state of the machines while they are operating. This connectivity allows them to predict future asset failures accurately and strategically schedule maintenance activities in advance. The findings presented in this paper demonstrate that digital twin applications can reduce maintenance costs by 35% and machine uptime by 98%. It also presents case studies of DT application across different industries, and comparative study of positive impacts achieved through DT adoption. Cumulatively, the study highlights DT's transformational capability to facilitate lean initiatives and demands further investigation into integrations of emerging technology for process improvement.
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How this classification was reachedexpand
Full frame distilled prediction
Teacher imitationNot calibrated prevalence, not ground truth. Human validation pending. Learned from the 10,348 direct Codex labels and 10,348 direct Gemma labels. Candidate is the union of thresholded teacher heads; consensus is their intersection. These outputs are machine_predicted_unvalidated and are not human labels or direct frontier model labels.
Codex and Gemma teacher scores by category
| Category | Codex | Gemma |
|---|---|---|
| Metaresearch | 0.000 | 0.000 |
| Meta-epidemiology (narrow) | 0.000 | 0.000 |
| Meta-epidemiology (broad) | 0.000 | 0.000 |
| Bibliometrics | 0.000 | 0.000 |
| Science and technology studies | 0.000 | 0.000 |
| Scholarly communication | 0.000 | 0.001 |
| Open science | 0.000 | 0.000 |
| Research integrity | 0.000 | 0.000 |
| Insufficient payload (model declined to judge) | 0.000 | 0.000 |
Machine scores (provisional)
The two teacher heads of the student model, read on this work. A score orders the frame for review; it never asserts a category, and the validation status ships verbatim with every row.
Baseline scores from an immature model (maturity gate not passed, 7 training rounds). Scores rank; they never assert a category.
score_only:v0-immature-baseline · verbatim from the scoring run: score_only means the number may rank works, and no category label ships from itClassification
machine, unvalidatedMachine predicted; a candidate call from one teacher head, not a consensus.
How this classification was reached, model by model and score by score, is at the end of the page under "How this classification was reached".