Feasibility of digital twins to manage the operational risks in the production of a ready-mix concrete plant

Abstract

The ready-mix concrete supply chain is highly disruptive due to its product perishability and Just-in-Time (JIT) production style. A lack of technology makes the ready-mix concrete (RMC) industry suffer from frequent production failures, ultimately causing high customer dissatisfaction and loss of revenues. In this paper, we propose the first-ever digital twin (DT) system in the RMC industry that can serve as a decision support tool to manage production risk efficiently and effectively via predictive maintenance. This study focuses on the feasibility of digital twins for the RMC industry in three main areas holistically: (1) the technical feasibility of the digital twin system for ready-mix concrete plant production risk management; (2) the business value of the proposed product to the construction industry; (3) the challenges of implementation in the real-world RMC industry. The proposed digital twin system consists of three main phases: (1) an IoT system to get the real-time production cycle times; (2) a digital twin operational working model with descriptive analytics; (3) an advanced analytical dashboard with predictive analytics to make predictive maintenance decisions. Our proposed digital twin solution can provide efficient and interpretable predictive maintenance insights in real time based on anomaly detection, production bottleneck identification, process disruption forecast and cycle time analysis. Finally, this study emphasizes that state-of-the-art solutions such as digital twins can effectively manage the production risks of ready-mix concrete plants by automatically detecting and predicting the bottlenecks without waiting until a production failure happens to react.