DTScribe: Generating Models for Digital Twin Reporting using Local Large Language Models

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.

LLM-assisted modeling holds the potential to rapidly build executable Digital Twins of complex systems from only coarse descriptions and sensor data. However, resilience to LLM hallucination, human oversight, and real-time model adaptability remain challenging and often mutually conflicting requirements. We present three critical design principles for integrating resilience and oversight into such workflows, derived from insights gained through our work on FactoryFlow - an open-source LLM-assisted framework for building simulation-based Digital Twins of manufacturing systems. First, orthogonalize structural modeling and parameter fitting. Structural descriptions (components, interconnections) are LLM-translated from coarse natural language to an intermediate representation (IR) with human visualization and validation, which is algorithmically converted to the final model. Parameter inference, in contrast, operates continuously on sensor data streams with expert-tunable controls. Second, restrict the model IR to interconnections of parameterized, pre-validated library components rather than monolithic simulation code, enabling interpretability and error-resilience. Third, and most important, is to use a density-preserving IR. When IR descriptions expand dramatically from compact inputs hallucination errors accumulate proportionally. We present the case for Python as a density-preserving IR : loops express regularity compactly, classes capture hierarchy and composition, and the result remains highly readable while exploiting LLMs strong code generation capabilities. A key contribution is detailed characterization of LLM-induced errors across model descriptions of varying detail and complexity, revealing how IR choice critically impacts error rates. These insights provide actionable guidance for building resilient and transparent LLM-assisted simulation automation workflows.

Transmission system operators face rising complexity from renewable integration, reduced inertia, and tighter security margins. Large language models offer natural-language decision support, but their hallucinations, uncontrolled tool use, and weak traceability conflict with control room requirements. This paper presents a governance-aware agentic digital twin for transmission grid control rooms. The large language model only selects and parameterizes whitelisted analysis tools, and every proposed action passes through a governance layer that the model cannot bypass. The layer enforces four rules on every run. Only whitelisted tools execute. No run exceeds its step budget. No action with side effects executes without explicit operator approval. Every number in an answer is rendered by the layer from backend results with its unit, variable, and time. The rules are checked on a persistent audit trail for every run of a released 118-task benchmark, which covers analytics, simulation, multi-step workflows, and twelve families of adversarial inputs on a digital twin of the Greek transmission network. Across 590 runs of the primary model, tool selection reaches 96.5% and task success 93.7%, and all four rules hold without exception. In a separate three-repetition study across four large language models, 1416 runs in total, the rules again hold on every run, with an approximate 95% lower bound of 99.8%. Removing the layer makes the same model execute all 45 approval-requiring runs without authorization and leaves only 39.2% of its answers with backend-supported numbers. Enforcement costs 12 to 16 milliseconds per request.