Autonomous Model Lifecycle Management for Digital Twin-Based Manufacturing Control

Process twins provide real-time representations of entire production processes. By capturing how process steps interact, rather than monitoring a single machine in isolation as an asset-based digital twin does, they have the potential to drive efficiency gains across the whole process. However, developing a process twin is costly. It requires accurately modelling the entire production process: its process steps, the equipment and product-specific settings each step uses, and its process variations. The resulting model must then be bound to live operational data. We present FacProcessTwin, a system that leverages a large language model (LLM) to reduce this development time, building a process twin from a plant's process documentation and natural-language input from an operator. FacProcessTwin generates this complete process model and then automatically binds its process steps to live operational data. The generated model and its data bindings are rendered as an interactive process diagram through which manufacturing personnel can monitor and correct the system's autonomous decisions, such as resolving uncertainty at safety-critical binding steps. We evaluate FacProcessTwin through a real-world case study of an Australian food manufacturer, covering 16 production process flows that span chilled, frozen, and aseptic shelf-stable product categories and include process variations within the same product. The results show that FacProcessTwin generates these process models accurately (a mean F1 of 95.2% against ground truth) and builds each twin in roughly a sixth of the manual time. Its human-in-the-loop governance then keeps the safety-critical bindings correct: at ambiguous tags where a single-pass baseline silently mis-binds 75.0% of the time, FacProcessTwin defers to the operator and mis-binds none.

Digital Twins rely on surrogate models to mirror physical systems in real time, yet these models can degrade as operating conditions evolve, a phenomenon known as concept drift. Maintaining surrogate fidelity under drift, particularly when models must also capture aleatoric uncertainty, remains an open challenge. Existing adaptive frameworks lack principled mechanisms for detecting when updates are needed, for efficiently adapting models from limited streaming data, and for certifying that updates genuinely improve predictive performance. Here we present an adaptive Digital Twin framework that integrates a Fisher score--based multivariate drift detector, Low-Rank Adaptation (LoRA) for parameter-efficient continual learning, and a Mann--Whitney $U$ test for online statistical validation. The framework monitors surrogate-model confidence via Fisher score vectors, triggers targeted fine-tuning of fewer than 1% of model parameters upon drift detection, and statistically certifies predictive improvement before deploying the updated surrogate. Applied to a stochastic linear system and a directed energy deposition additive manufacturing process as case studies, the framework successfully detects distributional shifts with short delays and restores both predictive accuracy and uncertainty quantification under abrupt and incremental drift. These results establish a statistically rigorous and computationally tractable pathway for sustaining the trustworthiness of neural-network--based Digital Twins throughout their operational life cycle.

A key step toward autonomous industrial operation is the ability to create and reconfigure control policies from natural-language requirement specifications, with minimal or no manual redesign. In this setting, policy generation by AI agents can be a credible path when paired with a plant-aware validator (e.g., a digital twin) that can check generated candidate actions before execution. However, practical deployment is constrained by inference latency and compute footprint: large cloud-based models are often too slow, opaque, or data-sensitive for edge closed-loop use. This work investigates whether a compact Small Language Model (SLM) can be retrained for control reasoning and embedded in a validator-guided correction loop. We use a Qwen2.5-1.5B model aligned via Group Relative Policy Optimization (GRPO), combined with (i) an action agent, (ii) a symbolic/digital-twin-style validation layer, and (iii) a reprompting agent that iteratively steers outputs toward valid actions. In randomized thermal-control simulations (30 experiments with 500 steps each), the framework achieves 91.5% average action-alignment accuracy (86.3%--100% across cases) at 3.84,s mean inference latency. Under symbolic re-mapping, it maintains a 95% in-range rate, indicating robust physical regulation despite reduced token-level agreement. These results support SLM+validator architectures as a practical path toward reconfigurable autonomous control at the edge.