A growing need for adaptability
Manufacturers face an environment where unpredictability is the norm. Machine failures, shifting order priorities and volatile market conditions place pressure on shopfloors that must react quickly, reconfigure intelligently and protect productivity. Yet most businesses still struggle with fragmented data, isolated systems and limited visibility, which makes rapid decision-making difficult when disruptions occur.

Creating a connected foundation
This paper introduces an industrial pre-pilot that brings resilience to the shopfloor through a data and service ecosystem built on Asset Administration Shells (AAS), the Elements for IoT platform and the Pontus-X environment. Instead of exchanging sensitive raw data, the system uses Compute-to-Data to run containerised algorithms directly where the data resides, supporting both sovereignty and secure collaboration. Machine states, schedules and performance indicators are mapped into a unified resilience submodel, giving planners a transparent, real-time view of constraints and capabilities.

From disruption to informed action
A key contribution of the work is a new Severity of Failure method that quantifies the impact of machine breakdowns on the production schedule. Combined with a constraint-based scheduling tool, it enables the system to propose the most resilient plan by assessing both makespan and vulnerability. When a disturbance occurs, the architecture triggers automatic rescheduling, helping the shopfloor shift from reactive firefighting to adaptive operation.

Testing resilience in practice
The pre-pilot mirrors a real industrial setup using retrofit sensors, edge devices and ERP data from a steel processing site. This controlled environment allows safe experimentation with live operational data, making it possible to validate interoperability, data flow and reconfiguration logic before deployment at scale.

Laying the path for industrial adoption
The study demonstrates the feasibility of integrating data spaces, AAS and CtD into shopfloor decision-making, paving the way for resilient scheduling in real industrial environments.

This article is based on the peer-reviewed publication “Enhancing resilience on the shopfloor through data and service ecosystems – an industrial pre-pilot”, published in Procedia CIRP (Volume 136, 2025).