Optimisation of production processes and industrial digitalisation: Sanja Bojić, FTN, UNS

As part of the DanubeDNA project, a webinar was held under the title “Optimisation of production processes and industrial digitalisation”. One of the presentations, delivered by Prof. Dr. Sanja Bojić from the Faculty of Technical Sciences, University of Novi Sad, focused on the optimisation of production systems through material flow simulation, digital twins, and real-time production monitoring. Key Highlights: ________________________________________ Production Systems Challenges Prof. Dr. Sanja Bojić presented the main challenges faced by modern production systems, including more complex products, shorter product lifecycles, fluctuating demand, smaller batch sizes, supply chain instability, labour shortages, and sustainability pressures. The presentation emphasized that SMEs need smarter technologies, greater agility, and a skilled workforce in order to remain competitive. ________________________________________ Material Flow Simulation The presentation introduced material flow simulation as a digital representation of real production, logistics, and service systems. Simulation can be used for strategic, tactical, and operational planning, both when designing new systems and when optimising existing ones. Its main advantage is that it helps companies answer the question: “What will happen if?” ________________________________________ Optimisation of Existing and New Systems Prof. Dr. Bojić explained how simulation can help companies determine the utilization of resources, detect bottlenecks, analyse inventory levels, test potential solutions, and identify improvement priorities. For new systems, simulation supports layout planning, comparison of different technologies, optimisation of material flows, determination of the required number of employees, and realistic calculation of return on investment. ________________________________________ Digital Twins and MES Systems The presentation also introduced digital twins as an advanced technology for decision-making and management in smart and agile manufacturing. It explained how continuous optimisation of production efficiency can be achieved by connecting material flow simulation with real-time production monitoring through Manufacturing Execution Systems, or MES systems. ________________________________________ DigiPro MES Solution and Case Study Prof. Dr. Bojić presented DigiPro MES as a solution developed for production SMEs. The system connects work orders, machines, and employees, collects real-time production data, supports production planning and monitoring, distributes work orders through an operator application, and includes an interactive knowledge base and AI-based analytics. A good practice case study of Uniplast Ltd. showed how the combination of DigiPro MES and Tecnomatix Plant Simulation can support real-time monitoring, what-if scenario testing, downtime reduction, and better management of production processes. ________________________________________ The DanubeDNA project supports small and medium-sized enterprises in the Danube Region in their digital transformation by developing practical digital tools, testing solutions in real business environments, and transferring knowledge through webinars and training activities. The project focuses on strengthening SME competitiveness, supporting industrial transformation, improving data-driven decision-making, and encouraging the transition towards Industry 4.0. The Croatian consortium partner in the project is TERA Tehnopolis d.o.o. This project is supported by the Interreg Danube Region Programme, co-financed by the European Union.