A digital twin-driven framework for full lifecycle operation and maintenance of smart production lines

Abstract

The increasing complexity of smart production lines demands intelligent and lifecycle-aware approaches to operation and maintenance (O and M). Digital twin (DT) technology, which creates high-fidelity virtual replicas of physical systems, offers a promising paradigm for real-time monitoring, predictive maintenance, and continuous optimization. However, existing DT applications predominantly address isolated lifecycle phases without providing a unified framework. This paper proposes a Digital Twin-Driven Full Lifecycle O and M Framework (DT-FLOM) for smart production lines, encompassing four phases: virtual commissioning, real-time operational monitoring, predictive maintenance and health management, and continuous performance optimization. The framework is validated through retrospective analysis of publicly reported DT implementations in discrete manufacturing. This study provides a systematic reference for deploying DT-driven O and M strategies in Industry 4.0 smart production environments.