Live Digital Twin for Shop Floor Management

  • Unique Paper ID: 197496
  • Volume: 12
  • Issue: 11
  • PageNo: 6445-6450
  • Abstract:
  • Modern manufacturing demands real-time visibility and data-driven decision-making to sustain competitive advantage. This paper presents a Live Digital Twin system developed for shop floor monitoring, leveraging Total Productive Maintenance (TPM) metrics stored in a Microsoft SQL Server Management Studio (MS SSMS) database. The proposed platform dynamically mirrors physical machine activity by ingesting live data and delivering real-time visibility into key performance indicators (KPIs) such as total parts produced, average cycle time, average load/unload time, and machine status (Active, Idle, or Stopped). The system architecture integrates physical machines with sensors, a network layer (Ethernet/Wi-Fi), a backend SQL server, and an interactive dashboard. Experimental results demonstrate that the Live Digital Twin significantly reduces response time to anomalies, improves Overall Equipment Effectiveness (OEE), and enhances preventive maintenance scheduling. The platform bridges the gap between shop floor operations and management oversight, enabling proactive, real-time intervention in manufacturing processes.

Copyright & License

Copyright © 2026 Authors retain the copyright of this article. This article is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.

BibTeX

@article{197496,
        author = {Pari Vinay Borkar and Shanmukhasudheer Yarra and Sanket Kasturiwala},
        title = {Live Digital Twin for Shop Floor Management},
        journal = {International Journal of Innovative Research in Technology},
        year = {2026},
        volume = {12},
        number = {11},
        pages = {6445-6450},
        issn = {2349-6002},
        url = {https://ijirt.org/article?manuscript=197496},
        abstract = {Modern manufacturing demands real-time visibility and data-driven decision-making to sustain competitive advantage. This paper presents a Live Digital Twin system developed for shop floor monitoring, leveraging Total Productive Maintenance (TPM) metrics stored in a Microsoft SQL Server Management Studio (MS SSMS) database. The proposed platform dynamically mirrors physical machine activity by ingesting live data and delivering real-time visibility into key performance indicators (KPIs) such as total parts produced, average cycle time, average load/unload time, and machine status (Active, Idle, or Stopped). The system architecture integrates physical machines with sensors, a network layer (Ethernet/Wi-Fi), a backend SQL server, and an interactive dashboard. Experimental results demonstrate that the Live Digital Twin significantly reduces response time to anomalies, improves Overall Equipment Effectiveness (OEE), and enhances preventive maintenance scheduling. The platform bridges the gap between shop floor operations and management oversight, enabling proactive, real-time intervention in manufacturing processes.},
        keywords = {Digital Twin, Live Digital Twin, MS SQL Server, OEE, Shop Floor Monitoring, Total Productive Maintenance (TPM).},
        month = {April},
        }

Cite This Article

Borkar, P. V., & Yarra, S., & Kasturiwala, S. (2026). Live Digital Twin for Shop Floor Management. International Journal of Innovative Research in Technology (IJIRT). https://doi.org/doi.org/10.64643/IJIRTV12I11-197496-459

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