Low-cost data integration framework for integration with simulation-as-a-service digital twins for make-to-order manufacturing SME

Small and medium enterprises (SMEs) face major challenges when implementing Digital Twin (DT) technology due to highinfrastructure costs and complex integration requirements. While the development of comprehensive DT models remains anexpensive, resource-intensive activity, most issues often lie in the complex integration processes required to connect existingmanufacturing systems with simulation environments. This paper presents a novel low-cost data architecture for integrating datafrom enterprise manufacturing systems (such as MES and WMS) into external simulation-as-a-service platforms, facilitating DTintegration while cutting the related costs. The proposed methodology addresses the challenge of connecting different IT systemswith simulation services through a data-driven integration approach. Rather than relying on expensive enterprise integrationarchitectures, the solution leverages a simplified framework focusing on intelligent data transformation with minimal pressureon existing infrastructure. The integration strategy centers on comprehensive data modeling that standardizes how products,resources, and materials information are represented across heterogeneous systems for DT consumption, particularly addressingthe complexities of make-to-order environments where product-centric information requires flexible approaches. The work hasbeen validated through the implementation in a medium-sized manufacturing company, and it demonstrated simplicity and cost-effectiveness compared to traditional integration approaches. The data architecture successfully transformed production plans,workforce allocation data, and warehouse materials records from native formats into standardized simulation-ready models. Byisolating and addressing the integration complexity while utilizing existing simulation-as-a-service providers for thecomputationally intensive modeling aspects, the proposed methodology significantly reduces the overall burden of DTimplementation for SME, supporting the adoption of this technology through a cost-effective integration strategy.