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Data-Driven Decision-Making: Leveraging Digital Twins for Reprocessing in the Circular Factory

  • Nehal Afifi

    Nehal Afifi is a researcher at IPEK – Institute of Product Engineering – Chair of Power Tools and Machine Elements at Karlsruhe Institute of Technology (KIT). Her research focuses on the data-driven validation of machine elements, with a particular emphasis on statistical learning, machine learning, and deep learning techniques for testing and reliability assessment. As part of the research group “Mechatronic Machine Elements and System Reliability”, she contributes to sustainability, connectivity, and individualization by developing innovative data-driven approaches for the testing and validation of mechatronic systems. Her work also supports the vision of a Circular Factory, focusing on reliability modeling.

     EMAIL logo     , Victor Mas

    Victor Mas is a researcher at IPEK – Institute of Product Engineering – Chair of Power Tools and Machine Elements at Karlsruhe Institute of Technology (KIT). His research focuses on reliability testing, with an emphasis on gaining knowledge about subsystems, their interactions with other subsystems, and how these influence overall system reliability and functional behavior over time. As part of the research group “Mechatronic Machine Elements and System Reliability”, he contributes to sustainability, connectivity, and individualization by developing new analysis methods for the collection and interpretation of load curves at the subsystem level, as well as a test method to efficiently collect reference reliability data. His work also supports the vision of a Circular Factory, focusing on reliability testing.

         , Jonas Hemmerich

    Jonas Hemmerich is a researcher at IPEK – Institute of Product Engineering – Chair of Power Tools and Machine Elements at Karlsruhe Institute of Technology (KIT). His research focuses on the quantification process of relations between embodiment parameters and functional behavior, with particular emphasis on the integration of implicit design knowledge. As part of the research group “Design Methods”, his research contributes to the development and evaluation of needs-based design support for building and storing design knowledge.

         , Felix Leitenberger

    Felix Leitenberger is a researcher and team manager at IPEK – Institute of Product Engineering – Chair of Power Tools and Machine Elements. His research focuses on the validation of mechatronic systems, with particular emphasis on system reliability, cross-domain simulation modeling, and testing. As team manager of the research group “Mechatronic Machine Elements and System Reliability”, he and his team drive sustainability, connectivity, and individualization by developing innovative solutions for mechatronic systems. Their work also supports the vision of a Circular Factory, focusing on testing for reliability.

         , Luisa Hoffmann

    Luisa Hoffmann is a PhD student at the Institute for Industrial Information Technology at the Karlsruhe Institute of Technology, specializing in information fusion under the supervision of Professor Michael Heizmann.

         , Ali Darijani

    Ali Darijani is a researcher working with Prof. Dr.-Ing. habil. Jürgen Beyerer on the SFB1574.

         , Patric Grauberger

    Patric Grauberger is an academic advisor at the IPEK – Institute of Product Engineering − Chair of Power Tools and Machine Elements. He conducts research in the field of data-driven design research and functional modeling for the circular economy. From his career through vocational training, studies and doctorate to his currently aspired habilitation, the implementation of the models and methods developed in design research into practice is close to his heart.

         , Michael Heizmann

    Michael Heizmann is Professor of Mechatronic Measurement Systems at the Institute of Industrial Information Technology at the Karlsruhe Institute of Technology (KIT). His research interests include measurement science, machine vision, signal and image processing, image and information fusion and their applications.

         , Jürgen Beyerer

    Jürgen Beyerer has been a full professor for informatics at the Institute for Anthropomatics and Robotics at the Karlsruhe Institute of Technology (KIT) since March 2004 and director of the Fraunhofer Institute of Optronics, System Technologies and Image Exploitation IOSB in Ettlingen, Karlsruhe, Ilmenau, Görlitz, Lemgo, Oberkochen and Rostock. Research interests include automated visual inspection, signal and image processing, variable image acquisition and processing, active vision, metrology, information theory, fusion of data and information from heterogeneous sources, system theory, autonomous systems and automation.

         and Sven Matthiesen

    Sven Matthiesen is Professor and Head of Institute at IPEK – Institute of Product Engineering – Chair of Power Tools and Machine Elements. His research focuses on design methods, human-machine systems, mechatronic machine elements and system reliability. He is a DFG review board member, member of several scientific societies, former board member of WiGeP (Scientific Society of Product Development), author of over 200 scientific publications and as inventor involved in 18 patents from his time at HILTI Corporation and his current research on power tools.
Published/Copyright: March 27, 2025
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Zeitschrift für wirtschaftlichen Fabrikbetrieb
From the journal Zeitschrift für wirtschaftlichen Fabrikbetrieb Volume 120 Issue s1

Abstract

Circular factories must ensure the functionality and reliability of used components for recombination with other components or subsystems from the same or different product generations. This paper presents a data-driven decision-making framework integrating the Functional Behavior Model and System Reliability Model within a Digital Twin. Data from physical testing is continuously incorporated, simulating recombination scenarios and guiding decision-making on component reprocessing. An angle grinder is used as a case study for demonstration. The proposed framework enhances sustainability and supports the use of reprocessed components in products designed for primary markets.

Abstract

Kreislauffabriken müssen die Funktionalität und Zuverlässigkeit gebrauchter Komponenten für die Rekombination mit anderen Komponenten oder Subsystemen der gleichen oder anderer Produktgenerationen sicherstellen. In diesem Beitrag wird ein Framework zur datengetriebener Entscheidungsfindung vorgestellt, welches das funktionale Verhaltensmodell und das Systemzuverlässigkeitsmodell in einem digitalen Zwilling integriert. Es werden kontinuierlich Daten aus physischen Tests eingebunden, um Szenarien für die Rekombination zu simulieren und bei der Entscheidungsfindung für die Wiederaufbereitung von Komponenten zu unterstützen. Ein Winkelschleifer wird als Fallstudie zur Demonstration verwendet. Das vorgestellte Framework fördert die Nachhaltigkeit und unterstützt die Verwendung von wiederaufbereiteten Komponenten in Produkten, die für den Primärmarkt bestimmt sind.

Keywords: Circular Factory; Data-Driven Decision-Making; Digital Twin; Functional Behavior Model; System Reliability Model
Schlüsselwörter: Kreislauffabrik; Datengetriebene Entscheidungsfindung; Digitaler Zwilling; Funktionales Verhaltensmodell; Systemzuverlässigkeitsmodell

Note

This article is peer reviewed by the members of the ZWF Special Issue Advisory Board.

Phone: +49 (0) 721 608-48060

About the authors

Nehal Afifi

Nehal Afifi is a researcher at IPEK – Institute of Product Engineering – Chair of Power Tools and Machine Elements at Karlsruhe Institute of Technology (KIT). Her research focuses on the data-driven validation of machine elements, with a particular emphasis on statistical learning, machine learning, and deep learning techniques for testing and reliability assessment. As part of the research group “Mechatronic Machine Elements and System Reliability”, she contributes to sustainability, connectivity, and individualization by developing innovative data-driven approaches for the testing and validation of mechatronic systems. Her work also supports the vision of a Circular Factory, focusing on reliability modeling.

Victor Mas

Victor Mas is a researcher at IPEK – Institute of Product Engineering – Chair of Power Tools and Machine Elements at Karlsruhe Institute of Technology (KIT). His research focuses on reliability testing, with an emphasis on gaining knowledge about subsystems, their interactions with other subsystems, and how these influence overall system reliability and functional behavior over time. As part of the research group “Mechatronic Machine Elements and System Reliability”, he contributes to sustainability, connectivity, and individualization by developing new analysis methods for the collection and interpretation of load curves at the subsystem level, as well as a test method to efficiently collect reference reliability data. His work also supports the vision of a Circular Factory, focusing on reliability testing.

Jonas Hemmerich

Jonas Hemmerich is a researcher at IPEK – Institute of Product Engineering – Chair of Power Tools and Machine Elements at Karlsruhe Institute of Technology (KIT). His research focuses on the quantification process of relations between embodiment parameters and functional behavior, with particular emphasis on the integration of implicit design knowledge. As part of the research group “Design Methods”, his research contributes to the development and evaluation of needs-based design support for building and storing design knowledge.

Felix Leitenberger

Felix Leitenberger is a researcher and team manager at IPEK – Institute of Product Engineering – Chair of Power Tools and Machine Elements. His research focuses on the validation of mechatronic systems, with particular emphasis on system reliability, cross-domain simulation modeling, and testing. As team manager of the research group “Mechatronic Machine Elements and System Reliability”, he and his team drive sustainability, connectivity, and individualization by developing innovative solutions for mechatronic systems. Their work also supports the vision of a Circular Factory, focusing on testing for reliability.

Luisa Hoffmann

Luisa Hoffmann is a PhD student at the Institute for Industrial Information Technology at the Karlsruhe Institute of Technology, specializing in information fusion under the supervision of Professor Michael Heizmann.

Ali Darijani

Ali Darijani is a researcher working with Prof. Dr.-Ing. habil. Jürgen Beyerer on the SFB1574.

Dr.-Ing. Patric Grauberger

Patric Grauberger is an academic advisor at the IPEK – Institute of Product Engineering − Chair of Power Tools and Machine Elements. He conducts research in the field of data-driven design research and functional modeling for the circular economy. From his career through vocational training, studies and doctorate to his currently aspired habilitation, the implementation of the models and methods developed in design research into practice is close to his heart.

Prof. Dr.-Ing. Michael Heizmann

Michael Heizmann is Professor of Mechatronic Measurement Systems at the Institute of Industrial Information Technology at the Karlsruhe Institute of Technology (KIT). His research interests include measurement science, machine vision, signal and image processing, image and information fusion and their applications.

Jürgen Beyerer

Jürgen Beyerer has been a full professor for informatics at the Institute for Anthropomatics and Robotics at the Karlsruhe Institute of Technology (KIT) since March 2004 and director of the Fraunhofer Institute of Optronics, System Technologies and Image Exploitation IOSB in Ettlingen, Karlsruhe, Ilmenau, Görlitz, Lemgo, Oberkochen and Rostock. Research interests include automated visual inspection, signal and image processing, variable image acquisition and processing, active vision, metrology, information theory, fusion of data and information from heterogeneous sources, system theory, autonomous systems and automation.

Prof. Dr.-Ing. Sven Matthiesen

Sven Matthiesen is Professor and Head of Institute at IPEK – Institute of Product Engineering – Chair of Power Tools and Machine Elements. His research focuses on design methods, human-machine systems, mechatronic machine elements and system reliability. He is a DFG review board member, member of several scientific societies, former board member of WiGeP (Scientific Society of Product Development), author of over 200 scientific publications and as inventor involved in 18 patents from his time at HILTI Corporation and his current research on power tools.

Acknowledgment

This research was funded by the Deutsche Forschungsgemeinschaft (DFG, German Research Foundation) in the collaborative research center (CRC) 1574 “Circular Factory for the Perpetual Product” with the project ID 471687386. While preparing this work, the authors used AI tools such as deepl.com and grammarly.com to improve readability and language. After utilizing these tools, the authors reviewed and edited the content as necessary. The authors take full responsibility for the publication’s content. All authors have read and agreed to the published version of the manuscript.

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Published Online: 2025-03-27
Published in Print: 2025-03-20

© 2025 Nehal Afifi, Victor Mas, Jonas Hemmerich, Felix Leitenberger, Luisa Hoffmann, Ali Darijani, Patric Grauberger, Michael Heizmann, Jürgen Beyerer and Sven Matthiesen, publiziert von De Gruyter

Dieses Werk ist lizensiert unter einer Creative Commons Namensnennung 4.0 International Lizenz.

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https://doi.org/10.1515/zwf-2024-0160
Keywords for this article
Circular Factory; Data-Driven Decision-Making; Digital Twin; Functional Behavior Model; System Reliability Model
Creative Commons
BY 4.0

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  2. Grußwort
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