Digital thread. Data consistency as a building block of modern industry

An advanced data management architecture known as digital thread solves this problem. What is it, though? What specific benefits does it bring? And how does it underpin Industry 4.0 strategies? In this article, we offer some clear answers to those questions.

Digital thread is an integrated data flow architecture which builds a complete, cohesive history of a product throughout its lifecycle. It is a mechanism that provides continuous, two-way access to information for everyone who needs it. 
In practice, this means that data at every stage, from initial definitions in CAD, via simulations, manufacturing execution systems (MES) and quality control, to operation and service data, are interconnected and accessible. Digital thread builds an authoritative single source, or point, of truth (SSOT, SPOT), eliminating inconsistencies and errors arising from working on out-of-date or incomplete data.

Digital thread makes it possible to build a continuous flow of information between teams and tools. What this means in practice is that:

• every design decision has its digital source and context;
• every change is registered and can be tracked;
• data flows without information loss between teams, such as mechanical, electrical and software, for example.

Digital thread architecture is based on two main pillars:

·       system integration: this is the technical connection of a company’s critical IT platforms, like product lifecycle management (PLM), enterprise resource planning (ERP), supervisory control and data acquisition (SCADA) and MES. Integration breaks the information barrier, facilitating automation and the secure flow of data between systems that have previously been operating independently;

·       data traceability: this is a precise tracking capability that can be applied to every piece of information and its context throughout a product’s lifecycle. In practical terms, it facilitates instant identification of, for example, which batch of raw materials was used for the production of a particular item; what the machine parameters were during its manufacture; its entire service history.

Traceability = easier audits and validations.

Implementing a digital thread strategy translates into concrete, measurable results:

• process optimisation and cost reductions: automating data flow minimises the risk of human error, decreases the time needed to introduce changes to designs and limits repair costs and production downtime;
• data analysis and decision-making: managers and engineers have access to full, up-to-date data in real time. Strategic and operational decisions are made on the basis of facts, not assumptions;
• increased quality and compliance: complete identification simplifies quality monitoring at every stage and guarantees compliance with rigorous standards and regulations. This is crucial in sectors like aviation, automotive and medicine, for instance;
• proactive lifecycle management: analysing operational data from products in use, via the Internet of things (IoT) for example, makes it possible to implement predictive maintenance strategies and avoid breakdowns.

These two concepts are closely connected, but they aren’t identical.

• A digital twin is a dynamic, virtual representation of a physical product, process or system. Read more about digital twinning, visit Digital Solutions Project House | User-Friendly Solutions | MakoLab

• Digital thread is a communication structure and data stream that feeds information to a digital twin, enabling it to simulate, analyse and predict the behaviour of its physical counterpart in real time.

In short, digital thread supplies data that makes a digital twin more precise.

An example

In a factory utilising digital thread, data from IoT sensors such as temperature and machine vibration are automatically sent to the relevant digital twin, which then predicts wear and tear on parts and recommends servicing before a breakdown occurs.

From data to value. End-to-end support from MakoLab

In this, the era of Industry 4.0, an astonishing 90% of companies are struggling with scattered data. And that generates costs. Digital thread is more than just technology. It is a strategic foundation for digital transformation. At MakoLab, we bring every part of the data chain together, offering:

1. Comprehensive data governance and assessment.
2. Intelligent data processing: data anonymisation, data cleaning and big data.
3. Advanced analytics and integration: business intelligence and data architecture
4. Operational continuity: 24/7 support, data operations and data streaming.

Digital thread isn’t a single product that can be purchased and installed, but a strategy and an information architecture that underpins mature digital transformation. In providing complete data consistency and accessibility, it enables organisations to leverage the potential of technologies like AI, IoT and big data analytics to the full.

Is your organisation ready to take the next step in its digital transformation? Contact us to talk about digital thread strategy in your business.

Translated from the Polish by Caryl Swift