Abstract
This paper presents the validated system reference architecture of a digital platform that integrates production scheduling, renewable energy management, and demand-response services to enable energy-flexible manufacturing across facility networks. Building upon the conceptual framework introduced at APMS 2023, the architecture comprises six interconnected layers—Physical, Data Infrastructure, Digital Twin, Management, Aggregator, and Smart Grid—and has been fully implemented and validated across five diverse industrial use cases: automotive sealing profiles, solar collectors, diving equipment, printed circuit boards, and steel production. A Design Science approach, combining literature review on scalability-adaptability-replicability (SAR), use-case studies, implementation at five manufacturers, and an industry-validated SAR survey, enables both practical relevance and theoretical contribution. The platform demonstrates strong horizontal and vertical scalability, high component reusability (80%–100%), and seamless integration via standardized protocols—MQTT, REST and OPC-UA. Validation results include up to 17% energy reduction, 60% self-sufficiency, and near-zero CO 2 emissions in facility cluster scenarios. Layer-by-layer implementation details, information flows, and lessons learned from implementation and validation are provided. The architecture addresses key gaps in existing digital twin and
energy-management frameworks by delivering an interoperable, and empirically validated blueprint aligned with Industry 4.0 principles. It offers manufuactuers a replicable pathway to increase renewable energy adoption, optimize costs, and support grid stability while advancing research on scalable cyber-physical production systems.