Digital thread

What is digital thread?

It is a communication framework that connects data across the entire lifecycle of a product or process. From the initial product design and engineering to manufacturing processes, delivery, and even maintenance, the digital thread weaves together data and insights, creating a seamless, integrated flow of information.

What are the key components of digital thread?

There are four core components of digital thread which are broken down below:

1. Integration across the product lifecycle
   The digital thread connects every phase of a product's lifecycle, including:
   • Design and product development: Integrating CAD models, simulations, and design iterations.
   • Manufacturing: Linking production schedules, machine data, and quality control.
   • Operations and maintenance: Providing real-time performance data and predictive maintenance insights.
2. Integration with other systems
   For the digital thread to function effectively, it must seamlessly integrate with various systems, tools, and platforms, such as Product Lifecycle Management (PLM), Enterprise Resource Planning (ERP) (opens in new tab), Manufacturing Execution Systems (MES) (opens in new tab) and Supervisory Control and Data Acquisition (SCADA) (opens in new tab).
3. Data traceability and continuity
   The digital thread ensures data is consistent and traceable, enabling teams to track changes, analyze trends, and identify inefficiencies throughout the products' lifecycle.
4. Live traceability and analysis
   The digital thread enables real-time traceability analysis, a breakthrough that allows organizations to pinpoint inefficiencies, monitor quality, and ensure regulatory compliance across the value chain.

Digital thread vs. Digital twin

While the terms digital thread and digital twin are often used interchangeably, they serve different purposes. The digital twin is a virtual representation of a physical product or system, used for simulation, analysis, and control. On the other hand, the digital thread is the communication layer that enables the digital twin by providing a continuous flow of data. In essence, the digital thread supports the digital twin but has broader applications, particularly in Product Lifecycle Management (PLM).

Applications of digital thread

The digital thread has diverse applications across various industries, including:

• Aerospace: Enhancing the design, manufacturing, and maintenance of aircraft by providing real-time data and traceability.
• Automotive: Streamlining the production process and improving product quality through integrated data systems.
• Pharmaceuticals: Ensuring compliance and improving the efficiency of drug development and manufacturing.
• IoT smart manufacturing: Enabling smart factories with interconnected systems that optimize production and maintenance processes.

Key trends in digital thread

There are several emerging trends in digital thread but one worth noting is its blockchain integration. Digital thread's integration with the blockchain enhances traceability and transparency by providing an immutable record of data exchanges, crucial for industries like pharmaceuticals and aerospace.

Standards and rules for digital thread

To ensure compatibility and interoperability, the digital thread adheres to established standards, including:

• OPC UA (opens in new tab) and ISO 10303 (STEP) (opens in new tab): For seamless communication between systems.
• ISO 23247 (opens in new tab): For integrating the digital twin and digital thread.
• ISO 8000 (opens in new tab): For maintaining high data quality.
• ISO/IEC 270001 (opens in new tab): For robust security and data protection.

Considerations regarding digital thread

While the digital thread offers immense potential, implementing it comes with challenges. For example, data integration can be tricky because of the diversity between systems and formatting can be complex. Additionally, the interconnected nature of the digital threat increases vulnerability to cyber threats.