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(2021) 318–323
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54th
CIRP Conference on Manufacturing Systems
th
54 CIRP Conference on Manufacturing Systems
Digital thread in shipbuilding as a prerequisite for the digital twin
Digital thread inCIRP
28th shipbuilding as a prerequisite
Design Conference, forFrance
May 2018, Nantes, the digital twin
Konrad Jaguscha,*, Jan Sendera, David Jerichoa, Wilko Flüggeb
A new Fraunhofer Institute for Large Structures in Production Engineering IGP, Albert-Einstein-Str. 30, 18059 Rostock, Germany
methodology
a to analyze
Konrad Jagusch a,
the functional
*, Jan Sender a
and
, David Jericho a
physical
, Wilko architecture
Flüggeb
of
existingFraunhofer
products
University
for
of for
Rostock,
an
Large Chair
assembly
of Manufacturing
oriented
in ProductionTechnology,
product
EngineeringAlbert-Einstein-Str.
family
2, 18059
30,Rostock,
identification
Germany
b
a
Institute Structures IGP, Albert-Einstein-Str. 18059 Rostock, Germany
University of Rostock, Chair of Manufacturing Technology, Albert-Einstein-Str. 2, 18059 Rostock, Germany
b
* Corresponding author. Tel.: +49 381 / 49682-230; fax: +49 381 / 49682-12. E-mail address: [email protected]
* Corresponding author. Tel.: +49 381 / 49682-230; fax: +49 381 / 49682-12. E-mail address: [email protected]
Paul Stief *, Jean-Yves Dantan, Alain Etienne, Ali Siadat
Abstract École Nationale Supérieure d’Arts et Métiers, Arts et Métiers ParisTech, LCFC EA 4495, 4 Rue Augustin Fresnel, Metz 57078, France
Abstract
*Within the unique
Corresponding author.production,
Tel.: +33 3 the
87 37product and the
54 30; E-mail associated
address: components pass through each individual process phase from design to actual
[email protected]
manufacturing.
Within the unique Especially in shipbuilding,
production, the productparallel
and theprocess organization
associated componentsresultspass
in anthrough
iterativeeach
procedure, which
individual meansphase
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fromindividual
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are subject to many
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process control nevertheless,
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Abstract
shipbuilding and use itusing
individual processes for the digital thread
a digital twin. - a prerequisite for the digital twin. This paper presents an approach to map the digital thread in
shipbuilding and use it for the digital twin.
In
© today’s business environment,by the trend towards more product variety and customization is unbroken. Due to this development, the need of
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systems
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System
analyze
Peer-review under responsibility of the scientific committee of the 54 CIRP Conference on Manufacturing System in terms of the number and
a product or one product family on the physical level. Different th product families, however, may differ largely
nature of components.
Keywords: Shipbuilding; This
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assembly systems. Based on Datum Flow Chain, the physical structure of the products is analyzed. Functional subassemblies are identified, and
a1.functional
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trade. Competitive
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Keywords: Assembly; Design method; Family identification the sector
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recent years transformation
this, digital digital thread and hasdigital
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the industry
recent years todigital
achieve an optimum
thread and digital in terms of datahave
twin (DT) technology
entered DT dependence on digital continuity of data [13] requires the
support
the for design,
industry to achieve production
an optimum andinservices
terms of[5–7]. There are
data technology generation of a holistic
DT dependence approach
on digital to implementation
continuity of a digital
of data [13] requires the
1.support
Introduction
several challenges
for in transferring
design, production and servicesthese [5–7].
approaches
There are to of the product
thread.
generation range
Thisofisathe and
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approach for
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implementation a and/or
of of a DT.
digital
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several Parallel inprocess
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transferring heterogeneous
approaches system to assembled
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the implementation of a DT.in
Due to [8]
landscapes
shipbuilding. the fast process
and
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manual production
phases, in the domain
processes
heterogeneous make
system of modelling and analysis
2.1. Description is now
of the digital not only to cope with single
thread
communication
implementation
landscapes [8] andand anmanual
difficult ongoing
[9]. There trend of digitization
are various
production definitions
processes and
makein products, a limited
2.1. Description of product
the digital range
threador existing product families,
digitalization,
literature [10, manufacturing
implementation 11], with DT
difficult enterprises
[9].being
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as one
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identify possible optimization potentials in the existing causes difficulties regarding an efficient definition and
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production system, it is important to have a precise knowledge comparison of different product families. Addressing this
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10.1016/j.procir.2021.11.054
 Konrad Jagusch et al. / Procedia CIRP 104 (2021) 318–323 319
2 Konrad Jagusch, et al. / Procedia CIRP 00 (2021) 000–000

time data acquisition is required [24]. The approach of the DT

goes beyond pure data management, since active data
processing is assumed [26]. Furthermore, there is a distinction
between the simulation and a DT. If the simulation deals
exclusively with the investigation of behavior of the virtual
instance, the DT includes current information [27] and can be
used to investigate alternative scenarios [28]. This in turn
underlines the need for data collection and its inclusion, which
takes place in the digital thread.
In summary, DT is defined as a digital representation of a
physical instance, where the digital thread contains all
necessary information and data to create and update the DT. In
Fig 1. it is evident how a data enrichment of the DT is driven
by the thread.

3. Approach of a digital thread in shipbuilding

Literature analyses make the significance of the DT and

digital thread approaches visible. Furthermore, it becomes clear
that there is still a considerable research potential. This also
Fig. 1. Digital thread and digital twin (according to [17, 18])
includes studies on the use of DT and Digital Thread in the area
of production planning and, more broadly, in control of
data within the life cycle. Only on this basis traceability within production processes [10, 29]. An essential aspect here is
the digital thread can be guaranteed [15]. Therefore various presumed consistency of data, which is an obstacle in areas
models from individual disciplines must be linked with each such as shipbuilding. The shipbuilding industry has
other [19]. Roth recommends storing information in a uniform characteristics that, in addition to general challenges, make the
product model to ensure consistency. This uniform model can implementation of a digital thread difficult.
be managed by a Product Lifecycle Management (PLM) system
for example [20]. The overriding goal of the digital thread must 3.1. Properties of shipbuilding
be linking of all relevant data over the entire product lifecycle
[21]. Despite existing efforts to build identical ships, each end
Interdisciplinary communication is achieved with the product is unique [30], so that shipbuilding can be classified as
implementation of a digital thread [22]. This is accompanied by Engineer to Order (ETO) [8]. Despite efforts to automate
the provision of information at the right time in the right place production processes, a considerable part of the work is done
[14], which in turn is regarded as the basis for the DT [11, 22]. manually [9]. In this area, information acquisition and
Fig. 1. summarises the approaches of Lin and Miskinis [17, 18]. processing in particular pose a challenge. [31] Another
The systems employed, such as Manufacturing Execution characteristic of shipbuilding is that development, design and
System (MES) and Computer-Aided-Manufacturing (CAM) production phases are lagging behind the receipt of the
tools, enrich DT along the thread. As this paper focuses on customer order [32]. In order to counteract the enormous
product development and manufacturing, Fig 1. does not show development and implementation times of unique products,
the asset chain. In particular, Miskinis' addition of data along individual process phases overlap [33]. This means that
the Enterprise Value Chain [18] to the Digital Twin plays a production starts even before the finalization of the design
major role in this paper. The same applies to the dependency phase [9]. The overlapping and the early start result in an
influence on DT as outlined by Lin [17], which is the subject of information deficit [33, 34]. Due to this and the strong
the next section. integration of customer requirements throughout the entire
product development process, frequent subsequent adjustments
2.2. Digital Twin are made [8]. Thus the data is no longer valid [35].
Furthermore, a large number of systems is used during the
The original approach of a DT is to link a physical system implementation of a shipbuilding project, which leads to
with its virtual double [23]. The aim is to achieve synchronicity heterogeneity of the system landscape and the actual data [8].
between the physical and virtual instances to enable prediction, The following points consider the necessity of respecting the
monitoring or adaptation of behavior in the real environment. preceding properties:
Preschke and Eckhadt refer to both products and processes • Provision of up-to-date data despite parallel processing
[24]. Kunath et al. present, for example, a DT of a • Coordination of data enrichment within the different
manufacturing system [25]. Kritzinger et al. describe the digital levels
twin as the controlling instance of the physical counterpart. A • Cross-system communication
bidirectional information flow must be established. This
ensures that state changes cause the other instance to adapt
[10]. To enable this behavior and dynamic interventions, real-
320 Konrad Jagusch et al. / Procedia CIRP 104 (2021) 318–323
Konrad Jagusch, et al. / Procedia CIRP 00 (2021) 000–000 3

3.2. Data storage for the digital thread

The initial model shown in Fig. 1. serves as a basis for

discussion to develop a transferable approach of a digital
thread. As in the reference model developed by the Institut für
Fabrikbetriebslehre und Unternehmensforschung (IFU),
production forms intersection of product creation and order
processing [36]. The data from production innovation and
enterprise value chain converge at this point. It becomes clear
that the processes within the respective chain are sequential and
the previous process is outlined as completed. This is a strong
Fig. 2. Digital thread in shipbuilding
contrast to the common parallel process in shipbuilding. As a
result the risk of digital waste in shipbuilding increases [16] as
described by Himstedt . The transfer of data between the Subsequent changes to requirements, customer wishes or
individual systems does not take place once, but several times deficient initial data situation force adjustments within
and iteratively. The chance of data loss or faulty information individual process levels. These adjustments in turn force
transfer increases. In addition, dependencies between sub- reactions within the subsequent steps. Whether all phases have
processes mean additional work in processing, if they are not to be gone through again depends on the degree of adaptation
fully completed. This effect is intensified when adjustments are and overall progress within the product development process.
necessary downstream [37]. Regardless of the trigger, the adjustment of data results in the
Since many different systems are used in shipbuilding [8], loss of validity of already released statuses. All other work
central data storage of all information involved in the digital statuses shall also lose their validity. Far-reaching disruptions
thread is recommended. A disadvantage is the redundant data within the holistic process are the result. However, due to the
storage, as required information is stored in the respective data complexity of a ship, it is not recommended to synchronize
silo of a system as well as in the central administration. Despite every data change with the digital thread in real time.
falling prices for storage media, the costs in companies for data Regardless of whether it is an adjustment or an initial data
storage are growing, as administration and requirements are generation, information provided can trigger action steps for
becoming more cost-intensive [38]. Shipbuilding projects further systems. Synchronization only adds value when
generate enormous amounts of data due to the complexity. On adaptations are completed. In addition, data is subject to
the other hand, it is advantageous that only one interface to the iterative changes within a process level or within a system.
digital thread needs to be established per system. Alternatively, Incomplete information also leads to additional work described
the information can be stored in respective data silos. The by Gärtner [37].
digital thread must take care of logical linking of the data It is recommended to initiate synchronization after defined
within all silos involved. However, the access of a system to milestones are reached within a process step. When choosing
different data silos means that interfaces exist to all silos. This milestones, attention should be paid to flexibility and speed of
in turn results in a high administrative effort to make all reaction to interventions during the ongoing process. On the
relevant data accessible. Heterogeneity forces the other hand, milestones that are selected too tightly lead to the
recommendation of central data storage of all relevant described effect that information is incomplete and thus only
information. temporarily current data statuses are made available. If a single
In addition to data storage, ensuring the consistency and component does not pass through production, milestones
synchronization of data in shipbuilding poses a higher risk for should be chosen in connection with data-related description of
the failure of the Digital Twin approach. assemblies. In shipbuilding, a wide variety of assemblies are
created [39], so that, for example, the 1st order can be seen as
3.3. Synchronization of the data status a logical unit. If, on the other hand, only higher-order
assemblies are considered in subsequent processes, the
Based on central data storage, communication is limited to milestone regulation must be adapted to the n-th order
two partners involved. The digital thread and respective system accordingly. It must be taken into account that this prolongs
that transfers the corresponding information to the digital reaction times and makes communication processes and thus
thread. Subsequent changes to requirements, customer wishes the design of the digital thread more sluggish. If, however, a
or the deficient initial data situation force adjustments within single component has to be changed due to an adaptation, the
the individual process levels. These adjustments in turn force milestone logic must be adapted accordingly. However, this
reactions within the subsequent steps. Whether all phases have again depends strongly on the current progress of product
to be gone through again depends on the degree of adaptation development. Adaptations of components that affect
and the overall progress within the product development assemblies entail a complete new production of these.
process. Regardless of the trigger, the adjustment of data results The enrichment of the digital thread is organized based on the
in a loss of validity of already released statuses. approach described. The provision and retrieval is done via
respective system-side interfaces. Another point is cross-level
communication. On the one hand, this is mapped via pure data
synchronization. In addition, this is extended by
4 Konrad Jagusch, et al. / Procedia CIRP 00 (2021) 000–000
Konrad Jagusch et al. / Procedia CIRP 104 (2021) 318–323 321

transmission of the status of processes within separate levels.

Despite the fact that milestones are not reached, the process is
continued due to the parallelism of the subsequent steps. The
only way to prevent the creation of multiple threads running in
parallel is to increase transparency. For this reason, the Digital
Thread requires the provision of the individual process states.
Furthermore, the corresponding systems must be informed
about them. These statuses can, for example, communicate
pending adjustments, the start of these or the achievement of
milestones. Subsequent steps are to be coordinated because of
this. Furthermore, a lower data flow can be expected, as only
relevant data is retrieved and requests to the digital threads are
reduced, as they are triggered by statuses.
Fig. 3. visualizes the approach described. Among other things,
the various requests and data transfer processes become visible.
In addition, the reaction of a subsequent step that is triggered
by a necessary adaptation can be seen. Based on this specific
approach of a digital thread, further functions are possible via Fig. 3. Digital twin in shipbuilding for deriving measures for subsequent
adjustments
the realization of a digital thread.
must be available in real time at field level in order to enable a
4. Dependencies between digital thread and Digital Twin
worker control system outlined by Himstedt [16]. The relevant
data is again obtained from the digital thread, which represents
When designing the digital thread, all phases and levels of
the work statuses or results of previous work within process
the entire product creation process must be taken into account.
levels. The DT generates and evaluates the corresponding
The special feature in shipbuilding is that the final product is
measures.
simultaneously in all phases of the product creation process
from a defined point in time. The inclusion of information from
4.2. Approach of a Digital Twin for the development of
ongoing production therefore plays an overriding role. The
measures for subsequent adjustments
following sections explain this fact.
Requirements of dynamic or real-time capable data
4.1. Integration of the production level
acquisition [42] are difficult to achieve in the area of manual
production in shipbuilding [40]. Nevertheless, the data
The requirements for communication and data availability
situation must guarantee a sufficiently accurate representation
during the entire product development process discussed under
of the physical instance. Thus, real behavior can be investigated
3.3 apply to all process levels. As shown in Fig. 1. this also
accordingly. These investigations are necessary to generate and
includes data from current production. A DT presupposes
evaluate potential measures. In this respect, the DT or the
dynamic data acquisition [24]. However, this is associated with
holistic digital system serves as a decision-making aid for the
challenges, especially in areas with large manual process
production system [25].
elements [40]. These must be solved in connection with the
Fig. 4. shows how the approach operates. External
successful implementation of a digital thread and DT.
influences that affect the system cause adjustments in the
Especially since the communication of subsequent adjustments
running process. Individual reactions take place within the
during running production processes represents an enormous
levels, which, nevertheless, take into account the current data
potential for optimization [32, 41].
statuses of previous work steps. Communication of the
Only bidirectional communication or the linking of the digital
individual statuses, as in Fig. 3., has been dispensed with at this
with the physical levels exploit the full potential. Due to
point. However, this again has a decisive role in coordination
advancing production, the current state must be taken into
of data enrichment and coordination of individual processes.
account in all decisions in preceding process steps. The same
In addition to the advancing reaction process involving the
applies to provision of information within the production area
DT, the synchronization of both instances is essential. In most
that is relevant for the actual implementation of products.
cases, transmission of data or communication of current
Delays in communication or a time discrepancy between data
processing progress regarding the adjustment is insufficient
retrieval and use in turn lead to a loss of validity. Thus, again,
and prevents a flexible reaction. Even the announcement of
digitization of the entire information flow is considered a
changes affects production depending on current production
prerequisite for successful implementation. Approaches for this
progresses. Regardless of the pending finalization of the
are discussed in [40]. This is the base for deriving appropriate
product-relevant ones, the change forces the taking of first
measures and reacting to changes during the ongoing process.
measures. This in turn requires prompt communication. A
In turn these measures
procedure that prevents far-reaching disruptions for
downstream processes. This in turn creates an iterative process
322 Konrad Jagusch et al. / Procedia CIRP 104 (2021) 318–323
Konrad Jagusch, et al. / Procedia CIRP 00 (2021) 000–000 5

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