Digital Twin Technology Advancing Industry 4.0 and Industry 5.0 Across Sectors

Abstract

Digital Twin (DT) technology is revolutionizing industries by integrating the physical and digital realms, driving advancements in real-time monitoring, predictive analytics, and process optimization under Industry 4.0. With the emergence of Industry 5.0, DTs are expanding their roles, emphasizing human-centric innovation and sustainability. This review provides a comprehensive analysis of how DTs are transforming industrial practices and their potential to shape the next industrial paradigm. The study begins with an overview of Industry 5.0, contrasting its human-centric, sustainable goals with Industry 4.0's efficiency-driven framework. Ten enabling technologies, including DTs, collaborative robots, artificial intelligence, and extended reality, are examined alongside the challenges and opportunities of Industry 5.0. The principles and key concepts of DTs, such as real-time synchronization, feedback loops, and lifecycle management, are explored, emphasizing their ability to bridge innovation and operational excellence. DT applications in Industry 4.0 and their evolution in Industry 5.0 are analyzed, highlighting 10 technological integrations, including IoT, big data, blockchain, and edge computing. DTs' roles in fostering human-centric innovation and sustainable resource management are discussed. Applications of DTs across seven key sectors including manufacturing, infrastructure, energy, logistics, mining, agriculture, and healthcare are examined, showcasing their transformative impact. The benefits of DTs, such as enhanced efficiency, sustainability, and innovation, are discussed alongside challenges like data security, high costs, and standardization issues. The review concludes by highlighting the implications of DTs for fostering collaboration, resilience, and sustainability. Future research directions include integrating DTs with the industrial metaverse, cognitive twins, and ethical AI practices. As industries transition to Industry 5.0, DTs are positioned to enable sustainable, resilient, and human-centric operations, paving the way for a transformative and inclusive industrial future.