Basic Principles and Approaches in Building an Architectural Model of Digital Twins in the Manufacturing Industry

Abstract

In the context of the digital transformation of the manufacturing industry, there is an increasing need to create holistic architectural models of digital twins that integrate data from the operational to the managerial level. International standards and practical cases show that digital twins can transform production processes, increasing their efficiency and sustainability. The purpose of the study was to identify the basic principles and approaches to building an architectural model of digital twins in the manufacturing industry considering international standards, practical cases, and simulation results. The study was based on the analysis of the five-level architecture and empirical verification of its effectiveness in the environment of AnyLogic and the Python Software Foundation. The key functions of each level, the mechanisms for integrating data flows into centralised storage, and the role of the digital twin as a dynamic link between operational and management circuits were considered. It was established that the combination of “digital shadow – digital sample” ensures the adaptability of the system and high accuracy of forecasting production development scenarios. The simulation showed that consistent architectural integration reduces operating costs by up to 20%, increases total productivity by 12-15%, and reduces downtime by 25-30%. Verification using the example of the “Digital Mine” concept (Sight Power Inc.) confirmed the applicability of the proposed model in the mining industry and the possibility of its scaling into related industry segments. A comparative analysis of integration approaches (point automation and platform architecture) revealed the advantages of the latter, providing stability, transparency, and scalability. It was concluded that the architectural model of digital twins is not only a technological optimisation tool, but also a strategic element of digital transformation, forming the basis for Kazakhstan's long-term industrial policy. The practical significance of the study lies in the fact that its results can be used by industrial enterprises, developers of digital platforms, and government agencies in the design and implementation of digital twin architectures, ensuring increased efficiency of production systems, reduced operating costs and the development of a unified digital ecosystem of industry in Kazakhstan.