Digital Twins (DTs) are a core enabler of Industry 4.0 in manufacturing. Cognitive Digital Twins (CDTs), as an evolution, utilize services and tools towards enabling human-like cognitive capabilities in DTs. This paper proposes a conceptual framework for implementing CDTs to support resilience in production, i.e., to enable manufacturing systems to identify and handle anomalies and disruptive events in production processes and to support decisions to alleviate their consequences. Through analyzing five real-life production cases in different industries, similarities and differences in their corresponding needs are identified. Moreover, a connection between resilience and cognition is established. Further, a conceptual architecture is proposed that maps the tools materializing cognition within the DT core together with a cognitive process that enables resilience in production by utilizing CDTs.

Refineries execute a series of interlinked processes, where the product of one unit serves as the input to another process. Potential failures within these processes affect the quality of the end products, operational efficiency, and revenue of the entire refinery. In this context, implementation of a real-time cognitive module, referring to predictive machine learning models, enables the provision of equipment state monitoring services and the generation of decision-making for equipment operations. In this paper, we propose two machine learning models: (1) to forecast the amount of pentane (C5) content in the final product mixture; (2) to identify if C5 content exceeds the specification thresholds for the final product quality. We validate our approach using a use case from a real-world refinery. In addition, we develop a visualization to assess which features are considered most important during feature selection, and later by the machine learning models. Finally, we provide insights on the sensor values in the dataset, which help to identify the operational conditions for using such machine learning models.

The operation of any vessel includes risks, such as mechanical failure, collision, property loss, cargo loss, or damage. For modern container ships, safe navigation is challenging as the rate of innovation regarding design, speed profiles, and carrying capacity has experienced exponential growth over the past few years. Prevention of cargo loss in container ship liners is of high importance for the Maritime industry and the waterborne sector as it can lead to potentially disastrous, harmful, or even life-threatening outcomes for the crew, the shipping company, the marine environment, and aqua-culture. With the installment of onboard decision support system(s) (DSS) that will provide the required operational guidance to the vessel’s master, we aim to prevent and overcome such events. This paper explores cargo losses in container ships by employing a novel weather routing optimization DS framework that aims to identify excessive motions and accelerations caused by bad weather at specific times and locations; it also suggests alternative routes and, thus, ultimately prevents cargo loss and damage.