Manufacturing now operates in a landscape defined by volatility. The pandemic, shifting regulations and global market shocks exposed how vulnerable value chains become when data cannot move freely. The real challenge was not only the disrupted supply but also the lack of visibility across interconnected systems.

This sparked FLEX4RES, a Horizon Europe project that reframes resilience as a design challenge. It aims to help factories adjust rapidly, share knowledge securely and reconfigure operations without excessive cost.

What the framework solves

Most manufacturers still work in digital isolation. Data sits in separate systems, making it difficult to detect early risks or adapt processes in real time. The industrial data-spaces framework from FLEX4RES resolves this through trusted, sovereign data exchange based on Gaia-X and IDS principles. Central to the architecture are the Asset Administration Shell (AAS) and the Digital Twin, which together create a consistent, real-time representation of machines, tools and processes. This shared digital foundation enables visibility and coordination across the supply chain.

From data to decision

The Resilience Assessment Toolbox measures performance at the machine, factory and network levels. Using sensor data and anomaly detection, it highlights where flexibility is required and calculates the “penalty of change” for each reconfiguration scenario. This turns resilience into a measurable capability, enabling informed, proactive decision-making. Human-centred intelligence FLEX4RES also incorporates human expertise. AI and immersive technologies capture and learn from expert actions, offering reconfiguration guidance or fault alerts that support operators and speed up response.

Demonstrating impact

Tests in learning factories in Germany and Austria show the framework can coordinate production steps, respond to material or machine disruptions and propose alternative routes. The result is improved quality, reduced waste and progress towards zero-defect manufacturing

This article is based on the peer-reviewed publication “An industrial data-spaces framework for resilient manufacturing value chains”, published in Procedia CIRP (Volume 116, 2023) and available via ScienceDirect.