Connected Manufacturing and Autonomous Systems

Connected manufacturing connects machines, people, materials and business systems from end to end, so data flows in real time and decisions are made closer to the shop floor, boosting efficiency. It links robots, PLCs and sensors to MES, QMS and ERP systems, creating a continuous digital thread from design through production and service.

A smart factory uses real-time data to operate efficiently. For a connected worker, this means clear work instructions, real-time feedback and faster fixes to any issues.

With the 3DEXPERIENCE platform, connecting the virtual world of modeling and simulation to real operations becomes seamless. Teams work from the same data, see the same KPIs and act on live production insights instead of static reports.

The common production models in manufacturing are:

1. Job shop manufacturing
   • High-mix, low-volume production where flexibility matters, such as in aviation and marine components
   • Model-based process planning and flexible MES enable fast routing changes with full traceability to fix flaws
2. Repetitive manufacturing
   • High-volume standardized production, such as in electronics and toys
   • Line simulation, robotics planning and advanced scheduling optimize takt time, OEE and global synchronization
3. Discrete manufacturing
   • Assembly-line approach where workers and machines can adjust or configure each unit as items move through the line
   • It sits between job shop and repetitive manufacturing — combining efficiency with flexibility — tightly synchronized to stay coordinated while steps and cycle times continue to vary greatly. This applies in the manufacturing and medical devices industry.
4. Batch manufacturing
   • Production in defined lots, common in pharma, food and specialty chemicals
   • Connecting recipe definitions with execution systems ensures closed-loop quality and compliance 
5. Continuous manufacturing
   • Non-stop manufacturing processes such as refining or steel, chemical processing and pharmaceutical
   • Virtual twins and real-time monitoring reduce variability while protecting uptime and ensuring better product quality

Connected factories synchronize smart equipment, people and systems in real time — tightly integrating the physical factory and its manufacturing process with its virtual twin.

Machine status, quality test results, workforce activity and material flow are captured live and fed into the virtual twin to facilitate planning, scheduling and analytics on real production data, enabling closed-loop optimization.

Dassault Systèmes 3DEXPERIENCE platform seamlessly connects the physical and virtual factory through the virtual twins. This enables simulation before installation, live quality tracking and optimization of production schedules when conditions change. Smart connected machines go beyond automation to sense changes, share data and adapt in real time.

The result? Factories that are both optimized and agile.

Connected industries extend digital continuity beyond plants, integrating OEMs, suppliers, partners and service networks across the entire value chain. Instead of optimizing in silos, companies share models and data from concept to recycling — coordinating design, manufacturing, logistics and service as one interconnected ecosystem. Dassault Systèmes orchestrates this vision on the 3DEXPERIENCE platform.

By unifying design with CATIA, simulation with SIMULIA, manufacturing with DELMIA, and lifecycle collaboration with ENOVIA, manufacturers move from isolated projects to a connected value network, accelerating innovation, resilience and sustainability.

Dassault Systèmes’ 3DEXPERIENCE platform and industry solution experience connect virtual planning with real-world execution. For example, manufacturers can design and simulate processes before deploying them, monitor performance metrics and detect anomalies in real time. This reduces rework, shortens development time, improves OEE and strengthens traceability.

Additionally, connected manufacturing powered by the platform gives manufacturers the visibility, speed and control to predict, validate virtually and improve decision-making, shifting operations from reactive to proactive. This is the real competitive edge that will set them apart as industry leaders.