In the context of Industry 4.0 and smart manufacturing, production factories are increasingly focusing on process optimization, high product customization, quality improvement, cost reduction, and energy saving by implementing a new type of digital solutions that are mainly driven by Internet of Things (IoT), artificial intelligence, big data, and cloud computing. By the adoption of the cyber–physical systems (CPSs) concept, today’s factories are gaining in synergy between the physical and the cyber worlds. As a fast-spreading concept, a digital twin is considered today as a robust solution for decision-making support and optimization. Alongside these benefits, sectors are still working to adopt this technology because of the complexity of modeling manufacturing operations as digital twins. In addition, attempting to use a digital twin for fully automatic decision-making adds yet another layer of complexity. This paper presents our framework for the implementation of a full-duplex (data and decisions) specific-purpose digital twin system for autonomous process control, with plastic injection molding as a practical use-case. Our approach is based on a combination of supervised learning and deep reinforcement learning models that allows for an automated updating of the virtual representation of the system, in addition to an intelligent decision-making process for operational metrics optimization. The suggested method allows for improvements in the product quality while lowering costs. The outcomes demonstrate how the suggested structure can produce high-quality output with the least amount of human involvement. This study shows how the digital twin technology can improve the productivity and effectiveness of production processes and advances the use of the technology in the industrial sector.

We developed a self-optimizing decision system that dynamically minimizes the overall energy consumption of an industrial process. Our model is based on a deep reinforcement learning (DRL) framework, adopting three reinforcement learning methods, namely: deep Q-network (DQN), proximal policy optimization (PPO), and advantage actor–critic (A2C) algorithms, combined with a self-predicting random forest model. This smart decision system is a physics-informed DRL that sets the key industrial input parameters to optimize energy consumption while ensuring the product quality based on desired output parameters. The system is self-improving and can increase its performances without further human assistance. We applied the approach to the process of heating tempered glass. Indeed, the identification and control of tempered glass parameters is a challenging task requiring expertise. In addition, optimizing energy consumption while dealing with this issue is of great value-added. The evaluation of the decision system under the three configurations has been performed and consequently, outcomes and conclusions have been explained in this paper. Our intelligent decision system provides an optimized set of parameters for the heating process within the acceptance limits while minimizing overall energy consumption. This work provides the necessary foundations to address energy optimization issues related to process parameterization from theory to practice and providing real industrial application; further research opens a new horizon towards intelligent and sustainable manufacturing.