With a new reference architecture, SmartFactory Kaiserslautern (SFKL) presents a central building block for the industrial future of Germany and Europe. The concept is intended to lay the foundation for intelligent, interoperable, and secure data networking of production, IT systems, and data rooms – thereby supporting the goals of the national Manufacturing-X initiative. One of the most important aspects of digitalization is the future-proofing of decisions and investments.

“Faster engineering and optimized processes”

According to the developers, the SmartFactory reference architecture implements the complete digitalization of production. “The spectrum ranges from edge-based, modular control technology to a uniform IT data layer to Agentic AI and also addresses open data ecosystems,” explains Prof. Martin Ruskowski, one of the creators of the architecture image. “Even the MX port principle from Manufacturing-X is already available as software from us. The individual elements interlock and ensure the future viability of the industry through faster engineering and optimized processes.”

Decisive contribution to IT/OT convergence

Industrial value creation is facing profound change. Global crises, skills shortages, and increasing regulatory requirements are putting more pressure on companies. To ensure long-term competitiveness and innovation, consistently networked, data-driven production systems are needed. This is exactly where the reference architecture comes in: it creates the technical basis for seamlessly connecting operational technology (OT) and information technology (IT) and exchanging data securely, interoperably, and independently of manufacturers. “We are addressing brownfield migration in particular,” emphasizes Simon Jungbluth, one of the authors of the recently published white paper ‘SmartFactory Reference Architecture’. “We want to show that digitalization does not automatically mean purchasing completely new equipment, but that even low-cost algorithms can contribute significantly to optimization.”

Digital twin-driven manufacturing in five steps

“With the SmartFactory Reference Architecture, we show how factories can think and act in the future – networked, flexible, and intelligent,” explains Ruskowski. “It is a practical guide for companies on their way to a networked data economy. Of course, we offer all kinds of support in the community or through the SmartFactory Academy.”

Self-assessment and goal setting

The article describes the five steps to a self-organizing factory based on digital twins. Specifically, these are: creating a digital foundation, utilizing data, optimizing processes, decentralized control, and self-organization. This enables companies to conduct a self-assessment and set their own goals. “The self-organizing factory is not created by a technological leap, but by a planned, multi-stage transformation process,” summarizes Ruskowski, emphasizing: “We are not saying that every factory must ultimately be self-organizing. Companies know their own goals best. We just want to support them on the way there.”

Home of Next Gen Factory Automation

The three-layer architecture model—consisting of OT, IT/OT coupling, and IT layers—enables consistent integration of machines, edge devices, and cloud applications. Standardized technologies such as OPC UA, AutomationML, and the administration shell (VWS) form the basis for interoperability, modularity, and secure data flows.

Putting principles into practice

In addition, the application example of the PHUKET production island shows how these principles can be put into practice: Smart machines control themselves, AI agents take over flexible production planning, and data is linked in real time via standardized interfaces. “That's why we chose the slogan ‘Home of Next Gen Factory Automation,’” says Jungbluth. “Because we are already applying these principles.”

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