Bridging Model-Based Systems Engineering, Digital Twins, and Cyber-Physical Manufacturing Systems: A Foundational Framework for Operational Excellence
Keywords:
Model-Based Systems Engineering, Digital Twin, Manufacturing Operations Management, Digital Thread, Dynamic Digital Thread Framework (DDTF)Abstract
The accelerating complexity of modern manufacturing demands a unified approach to align system design, operational execution, and continuous improvement. Model-Based Systems Engineering (MBSE), Digital Twins (DTs), and Manufacturing Operations Management (MOM) each contribute critical but fragmented capabilities across this continuum, while Cyber-Physical Systems (CPS) enable real-time coupling between digital and physical layers. Despite their conceptual complementarity, the literature lacks an integrative framework that connects these domains into a continuous information and decision flow supporting Operational Excellence. This paper conducts a systematic bibliographic synthesis of 97 peer-reviewed studies and standards (INCOSE, ISO 23247, ISA-95) to develop the Dynamic Digital Thread Framework (DDTF)—a foundational architecture for digitally continuous, cyber-physical manufacturing ecosystems. The DDTF aligns MBSE’s model-centric discipline with DT’s analytical intelligence, MOM’s executional control, and CPS’s real-time adaptability. Through this integration, the framework operationalizes Lean and Six Sigma principles within a digital architecture capable of reducing conversion cost, synchronizing the 4Ms (Man, Machine, Material, Method), and eliminating non-value-added activities.
The study contributes a theoretically grounded yet industry-relevant foundation for future empirical research on digital continuity and cyber-physical integration. By reframing digital transformation as a systemic redefinition of knowledge flow and decision logic—rather than a technology deployment—the DDTF establishes a conceptual bridge between engineering intent and operational reality, enabling sustainable Operational Excellence in the era of Industry 5.0.
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