Digital Thread explained simply
Imagine you had an invisible, digital red thread that runs through every phase of a product – from the first sketch in the engineering office, through manufacturing, to maintenance and finally to the end of the lifecycle. That is exactly what the Digital Thread is: it links all information and systems along the entire product lifecycle, so that everything is networked, seamless and traceable at any time. No more data silos – instead, a continuous flow of information that accelerates decisions, ensures quality and enables flexibility.
Background information
Digital Thread is a data-driven architecture that connects information about a product along the entire lifecycle – from design through manufacturing to maintenance and field service. It ensures that data does not reside in isolated systems, but is available in a continuous, contextual flow.
A Digital Thread enables:
- Transparency and consistency – all departments access the same data.
- Collaboration and efficiency – handovers without data loss or media discontinuity.
- Integration of IT systems – CAD, PLM, MES, ERP and IIoT work together in a coherent data flow.
Digital Thread vs Digital TwinDigital model of physical objects with continuous data connection for analysis and prediction. – commonalities & differences
Although the terms are often mentioned together, Digital Thread and Digital Twin follow different concepts, which however reinforce each other:
- Digital Thread
- Focus on data flow and connectivity.
- Links information along the entire product lifecycle.
- Creates transparency and traceability from development to decommissioning.
- Digital Twin
- Focus on virtual representation.
- Digitally replicates a physical object, often synchronised in real time.
- Enables simulation, prediction and optimisation based on a digital model.
Commonalities:
- Both concepts are based on current, consistent data.
- They use sensors, IoT and cloud technologies as their foundation.
- The goal is higher efficiency, quality and flexibility in industry.
Synergy:
The Digital Thread provides the continuous data flows that keep the Digital Twin constantly up to date. Conversely, the Twin generates simulation results that can be fed back into the Thread. Taken together, the two form a complete, closed data and information architecture.
Technology stacks and platforms
A Digital Thread is not a single product, but a technological ecosystem. Important building blocks are:
- PLMProduct Lifecycle Management - management of all product data and processes from initial concept to disposal. systems (Product Lifecycle Management): form the basis for product data management, versioning and change tracking.
- CAD & CAE systems: design and development data are often the starting point of the thread.
- MESManufacturing Execution System - software for real-time control and monitoring of entire production. systems (Manufacturing Execution Systems): incorporate manufacturing data and process information to create transparency about production workflows.
- ERPEnterprise Resource Planning - software for integrated management of all business processes and resources. systems (Enterprise Resource Planning): ensure that planning, resources and logistics are integrated into the thread.
- IIoTIIoT is the internet-based networking of industrial machines, systems, and devices for data collection and process optimization. platforms: transmit sensor data and operational information from machine parks and production lines in real time.
- Cloud & knowledge graph platforms: enable continuous storage, linking and analysis of large volumes of data.
- APIs & standards: interfaces such as OPC UA, REST or MQTT ensure interoperability between heterogeneous systems.
Practical example:
A CAD model of a motor is transferred into a PLM system. Production parameters from the MES, bills of materials from the ERP and operational data from the IIoT platform complement the data flow. The result: a consistent, continuous “thread” that provides all stakeholders with the same information.nformation.