The AMRC’s expertise across multiple capabilities puts us at the forefront of understanding and untangling the digital thread. But what is it, why does it matter and what is the AMRC’s vision in this space? Gavin Hill, senior theme lead for digital at the University of Sheffield AMRC, writes.  

Article featured in the latest issue of the AMRC Journal.

‘Data is the new oil.’ Most of us have heard this phrase, coined by British mathematician, University of Sheffield alumni and entrepreneur Clive Humby, emphasising the immense value of data in today's world. Humby didn't stop there though: ‘...Like oil, data is valuable, but if unrefined, it cannot really be used.’ This insight pushes us to go beyond collecting data and focus on refining it into actionable information. This is where the digital thread starts to play a part in the analogy.

Just as oil gains value through refining, supplementing and being transported closer to where it’s needed, the digital thread enhances data value. By creating a continuous data pipeline for a process, service, or product, throughout its lifecycle, we enable its potential future value. 

At different stages, we add context to the data, allowing us to use information such as material characteristics, machinability and in-use performance to make better informed decisions. This might result in adjusting supply chains or altering product usage guidance. Essentially, the digital thread allows us to extract more value from our data. 

The digital thread of a product is the flow of data throughout the lifecycle of the product, which provides a single, accessible data source. It can encompass all relevant data about a product, from its design and manufacturing, to its performance in the field and disassembly or second life. 

The existing digital thread of most products isn’t perfect, but the effort of research in the space is about making it easier to adopt and clearing the way for us to have a  more valuable digital thread. 

As an example, consider a clicky pen. The ideal, yet vastly overengineered digital thread for this pen would include materials data, design specifications, manufacturing processes and even how often it has been clicked, through to disposal and recycling possibilities. This comprehensive data integration allows for continuous improvement of the design of the pen and the processes used to make it.

While here we take the example of using such an all encompassing digital thread for a pen, its true potential is realised in complex products like ships, smart buildings, planes or uncrewed aerial vehicles (UAVs). 

Imagine a world where we can disassemble a vehicle at the end of its life, knowing exactly which parts can be reused, based on their history. We could know which parts can be recycled using emergent technologies and identify exactly how many tonnes of carbon dioxide were used to create and operate the vehicle. That is what a complete digital thread enables.

Interoperability can be difficult when adopting burgeoning technologies like Internet of Things (IoT), artificial intelligence (AI), and cyber-physical systems into a manufacturing environment. The digital thread acts as a conduit,supporting the seamless integration of these technologies to enhance manufacturing processes - without it, fully realising the benefits of Industry 4.0 would be challenging, if not impossible. This is the driver behind the AMRC’s research investment in this space. 

As with an oil pipeline, there are different ways to approach the implementation of the digital thread in manufacturing. Many large manufacturers rely on established manufacturing execution systems (MES) and product lifecycle management (PLM) systems from industry giants like Dassault Systèmes, PTC and Siemens to enable their digital thread. These systems are akin to the well-established, existing, oil pipelines. While reliable, they require significant investment and maintenance, which can slow down innovation and adaptation.

For many small and medium-sized enterprises, the cost of traditional MES and PLM systems is prohibitive. This has led to the emergence of new players offering Software-as-a-Service (SaaS) models with cloud-native functionalities for enabling the digital thread. These solutions are more cost-effective and adaptable, similar to buying a new, modern, plastic pipeline to transport your oil, that is easier to maintain and upgrade than the traditional pipe.

The most radical approach involves questioning the very data models and foundations upon which current MES and PLM systems are built, down to their fundamental building blocks. This is like questioning the foundational aspects of our oil pipeline - if we should alter the pipe’s profile, use a new pipe, or even transfer the oil as a gas instead. 

At the AMRC, which is part of the national network of High Value Manufacturing Catapult research centres, we've been exploring the digital thread concept for years - even before we knew what it was.  Our research spans various aspects of the manufacturing lifecycle, providing valuable insights and advancements in this field. 

We’ve taken efforts to enact research that views the digital thread problem from all three of the angles described above, because we know we need to support all types of manufacturers and understand how different the landscape may be in the not too distant future. Our activities include:

• Automating the transition from computer-aided design (CAD) to optimised computer-aided manufacturing (CAM) programs for machine tools. This key research focus requires a robust digital thread to provide the necessary data for creating precise CAM programs and enable feedback from machining centres. 
• Working with companies including Rolls-Royce and BAE Systems to optimise data transfer within supply chains through the connected model-based engineering environment programme. The AMRC is working with BAE Systems, Rolls-Royce, Siemens, National Physical Laboratory and HVM Catapult partner the National Composites Centre. This ensures data, such as geometric dimensioning and tolerancing annotations within CAD models, can be transferred accurately, regardless of the PLM or CAD system used. This confirms the integrity of a digital thread between suppliers. 
• Our Factory+ project using a Unified Namespace (UNS) approach built on open-source components to enable seamless data exchange within a manufacturing facility. This project is a blueprint for future factory connectivity and a critical enabler of the digital thread.
• Partnering with Siemens to deploy MES and PLM systems, providing a robust foundation for our digital thread research. Additionally, we're expanding our collaborations with Dassault Systèmes and PTC to allow us to utilise their tools in this space and support a wider set of industrial demands.
• Investigating data structures and representation, leveraging concepts and technologies like ontologies, 4D modelling and SysML V2. This foundational research aims to influence future software offerings to meet the holistic needs of the manufacturing community.
• The AMRC’S UAV project, which serves as a practical application of the digital thread concept. By focusing on design elements and incorporating tools like hardware in the loop (HIL) and interactive simulation analysis, we are gaining valuable insights into the effort required to implement a comprehensive digital thread in complex systems.

The AMRC toolkits UAV demonstrator, which went to the MACH 2024 exhibition to serve as a visual and tangible focal point for our digital thread work. It has allowed us to understand the difficulties, opportunities and positives that come with implementing a digital thread for a product and the software stacks that stand behind it. 

The UAV will continue to act as a platform for our core research for years to come. We will be using the next two years to build a digital thread from requirements, through to the manufacturing stage - with the addition of specialised views into applying it in areas like machining, composites and additive manufacturing. 

The key is that the UAV is in the public domain meaning that manufacturers, academics and anyone else can learn from it and engages with us to help guide the future direction of that research to make sure it is as beneficial as possible for UK manufacturers. 

Looking ahead, our goal is to have all the necessary data available at the right time to enable optimal decision-making for a manufacturer, automating many of those decisions. This requires interoperable and modular software that can adapt to changing needs and preferences.

Over the next 12 months, we will focus on building a broad-based understanding of the digital thread within the AMRC and the wider manufacturing community - educating stakeholders and addressing knowledge gaps. We will work closely with industry partners to understand their pain points and align our research efforts with their needs. This collaborative approach will ensure our research is relevant and impactful.

We will enhance our technical capabilities by recruiting experts and investing in key areas of research, including deepening our understanding of digital requirements and manufacturing processes. We will continue to develop the UAV project by concentrating on specific sub-systems and the transition of their digital requirements through to the end of the design phase. This focused approach will provide valuable insights and practical applications for the digital thread.

In the long run, we aim to create a comprehensive digital data flow from raw materials to end-of-life for products. This involves integrating various digital systems and understanding the implications of any technical debt that comes along with them. By doing so, we will pave the way for a more efficient and sustainable manufacturing ecosystem.

The digital thread is not just a concept, but a transformative force in modern manufacturing. We are at the forefront of this transformation, exploring new technologies, rethinking data foundations and working closely with industry partners.  

Our journey is ongoing and we’re committed to advancing our understanding and implementation of the digital thread to drive innovation and excellence in manufacturing.