Advancing Industrial IoT and Industry 4.0 through Digital Twin Technologies: A comprehensive framework for intelligent manufacturing, real-time analytics and predictive maintenance

Keskar, Ankush (2025) Advancing Industrial IoT and Industry 4.0 through Digital Twin Technologies: A comprehensive framework for intelligent manufacturing, real-time analytics and predictive maintenance. World Journal of Advanced Engineering Technology and Sciences, 14 (1). pp. 228-240. ISSN 2582-8266

Digital Twin technology is advancing industries with an increasing ability to monitor dynamic systems, structures, operating processes, and assets in detail and in real-time. Key to Industry 4.0, Digital Twins allow the creation of virtual representations of actual settings, thus enabling analytical processing, prognosis, and management enhancement. To explain what Digital Twins are and their capabilities, this paper aims to identify their importance in intelligent manufacturing, real-time analysis, and maintenance predictions. It also describes the issues arising from Digital Twins implementation, including technical issues, data security, and change resistance, and offers ways of addressing these challenges. The further development of Digital Twin technology, other fields of AI, 5G, extensive technologies, and sustainability are also discussed in detail in the sequence. Finally, it has been found that Digital Twins are set to become the driving force of the subsequent industrial revolution based on improved, optimized, and environmentally friendly processes.