Implementations of Digital Transformation and Digital Twins: Exploring the Factory of the Future

In the era of rapid technological advancement and evolving industrial landscapes, embracing the concept of the factory of the future (FoF) is crucial for companies seeking to optimize efficiency, enhance productivity, and stay sustainable. This case study explores the concept of the FoF and its role in driving the energy transition and digital transformation within the automotive sector. By embracing advancements in technology and innovation, these factories aim to establish a smart, sustainable, inclusive, and resilient growth framework. The shift towards hybrid and electric vehicles necessitates significant adjustments in vehicle components and production processes. To achieve this, the adoption of lighter materials becomes imperative, and new technologies such as additive manufacturing (AM) and artificial intelligence (AI) are being adopted, facilitating enhanced efficiency and innovation within the factory environment. An important aspect of this paradigm involves the development and utilization of a modular, affordable, safe human–robot interaction and highly performant intelligent robot. The introduction of this intelligent robot aims to foster a higher degree of automation and efficiency through collaborative human–robot environments on the factory floor and production lines, specifically tailored to the automotive sector. By combining the strengths of human and robotic capabilities, the future factory aims to revolutionize manufacturing processes, ultimately driving the automotive industry towards a more sustainable and technologically advanced future. This study explores the implementation of automation and the initial strides toward transitioning from Industry 4.0 to 5.0, focusing on three recognized, large, and automotive companies operating in the north of Portugal.