Development of a Novel Retrofit Framework Considering Industry 4.0 Concepts: A Case Study of a Modular Production System

Retrofitting legacy systems provides significant advantages by addressing compatibility issues with new devices and technologies, meeting current process requirements, and increasing security and regulatory compliance. The process starts by collecting requirements and evaluating the legacy system’s attributes and limitations, followed by integrating modern technologies to improve efficiency, streamline processes, and enhancing performance and interoperability while leveraging existing facilities to reduce costs. A systematic approach ensures that updates align with modern technological standards, with performance evaluations conducted via qualitative and quantitative methods and system maturity assessed according to the Reference Architecture Model for Industries 4.0 (RAMI 4.0 model’s) criteria for intelligent factories. By incorporating digital twin (DT) capabilities, which replicate the physical state of systems and provide real-time data updates, the retrofit strategy aligns the physical system with Industry 4.0 contexts, facilitating continuous improvement and seamless integration with modern processes. The goal is to advance the legacy system technologically to ensure seamless integration with contemporary processes, validated through RAMI criteria analysis for smart factories. As part of this process, digital twin architecture was built. This architecture was the basis for building and operating digital twins in the process. The methodology was used to enhance and transform legacy systems, creating the foundation for creating a fully digital twin. Using this method, these systems can be updated to meet the requirements of Industry 4.0. This ensures that they can work with new systems and share data in real time, which improves general operations.