Digital Twin

We are currently developing a digital twin of Ford’s stamping manufacturing lines, which plays a key role in enhancing sustainability by promoting zero waste and energy efficiency. The digital twin collects real-time data, including mechanical properties of blanks, blank thickness, and lubrication thickness. Embedded load cells in the hydraulic press track forces during stamping, while a camera system monitors blank draw vectors after die opening, enabling continuous optimization of the process for zero waste manufacturing (ZWM).

We are also focused on large-scale implementation across high-volume manufacturing facilities. Our efforts include developing strategic approaches for storing and visualizing this data within corporate IT structures to ensure scalability and sustainability. A scalable platform is essential to avoid costly customization when expanding to additional press lines and facilities. While leading cloud providers like Google Cloud Platform (GCP), Amazon Web Services (AWS), and Microsoft Azure are integral to this process, concerns about data integrity and security remain, especially since much of the insights derived from this data are proprietary to manufacturing companies.