Data science methodologies are playing an increasingly important role in advancing manufacturing systems, enabling improvements in efficiency, energy usage, cost reduction, product quality, and predictive maintenance capabilities. This raises a fundamental question: to what extent can data models reshape manufacturing processes, and what limitations prevent their full-scale adoption? Recent developments show a growing integration of data models within digital twin and digital shadow architectures, facilitating real-time monitoring and decision-making. Nonetheless, the complexity of industrial processes and the scarcity of high-quality, well-structured datasets pose significant challenges, particularly in terms of model robustness, interpretability, and scalability. Importantly, the effectiveness of such models depends more on data quality and representativeness than on data quantity alone. This review presents a structured analysis of data modeling techniques for manufacturing applications, with emphasis on data generation, sampling, preprocessing, and modeling approaches across diverse operational regimes, including steady, transient, and generative processes.
Artificial Intelligence (AI) and Machine Learning (ML) are increasingly driving the digital transformation of manufacturing systems, enabling the transition from conventional process operation toward intelligent, adaptive, and data-centric production environments. This work presents the development of AI-enabled advisory systems for casting processes, integrating singular value decomposition (SVD)-based reduced-order models with a Variational Autoencoder with Arbitrary Conditioning (AC-VAE) and hybrid simulation frameworks to support real-time process prediction and optimization. The proposed approach leverages manufacturing data to establish predictive models capable of rapidly evaluating process conditions, optimizing operating parameters, and enhancing product quality while reducing material waste, energy consumption, and production costs. By combining physics-based understanding with AI-driven analytics, the framework facilitates real-time decision support, adaptive process control, and continuous performance improvement within modern manufacturing ecosystems. These capabilities contribute to the broader objectives of Industry 4.0 and emerging Industry 5.0 paradigms, including automation, connectivity, operational resilience, sustainability, and human-centered manufacturing. A representative Horizontal Direct Chill (HDC) continuous casting case study is presented to demonstrate the practical implementation of the framework, encompassing database generation, model training, validation, and deployment of predictive advisory tools for real-time manufacturing applications.
Sofija Milicic, A. Horr, S. Elgeti et al.· Processes· 0 citations
