Towards Sustainable Personalized Assembly Through Human-Centric Digital Twins

New trends in industry emphasize green and sustainable production on the one hand and personalized or individualized production on the other hand. Introducing new manufacturing technologies and materials to integrate the customer’s specific requirements into the product, while keeping the focus on environmental footprint, becomes a serious challenge. As a result, new production paradigms are developed to keep up with new trends. The most known Industry 4.0 paradigm is oriented towards new technologies and digitalization. Recently, Industry 5.0 appeared as a supplement to the existing Industry 4.0 paradigm, oriented to sustainability and the worker. A multidisciplinary approach is necessary to address these challenges. The Industry 5.0 paradigm’s main pillars—human centricity, resilience, and sustainability—are also pillars of the multidisciplinary approach used in this research. A human-centric approach includes workforce reskilling and acquiring new technologies to ensure that technology serves to enhance human work, while creating a supportive and inclusive work environment and prioritizing employee engagement and wellbeing. Resilience as a second pillar is related to the ability of manufacturing systems and processes to adapt to changing conditions to remain robust and flexible, and sustainability is an important and long-term requirement of this multidisciplinary approach. Based on the research part of the Erasmus+ ExCurS project, particularly research focused on application and training related to digital twins, an advanced concept of organizational sustainability is presented in this paper. The concept of organizational sustainability is realized through the usage of key digital twin technologies aligned with human-centric approaches. A new prototype of a digital twin that optimizes an assembly system based on a developed algorithm and humanoid decision-making is provided as a proof of concept. The human-centric digital twin for industrial application is presented through a case study of personalized products.