Proceedings of the 8th IEOM Bangladesh International Conference on Industrial Engineering and Operations Management, Dhaka, Bangladesh, December 20-21, 2025

Digital Twin-Driven Optimization On Production & Maintenance In The Emerging Steel Industry Of Bangladesh: A Lean Based Approach 

Quazi Monjur E-Elahi, Ridika Islam, Umme Ayesha Rahman, Jubayda Sultana Sezeel

Department of Mechanical and Production Engineering  
Ahsanullah University of Science and Technology (AUST)  
Dhaka, Bangladesh  

Abstract 

The steel industry in Bangladesh plays a critical role in driving national infrastructure, shipbuilding, and construction projects. Yet, the sector faces persistent challenges, including operational inefficiencies, frequent unplanned downtime, waste generation, and dependence on conventional practices. This paper introduces a Lean-based Digital Twin (DT) framework designed to address these barriers by integrating real-time simulation and predictive analytics with Lean Manufacturing principles. The proposed model leverages industrial IoT data, process simulations, and predictive maintenance to reduce unplanned stoppages, enhance machine availability, and optimize production efficiency. By embedding Lean tools such as Value Stream Mapping and Kaizen within the DT environment, the framework ensures systematic waste elimination and continuous process improvement. However, challenges such as high initial investment costs, infrastructure limitations, and skill development gaps must be addressed for effective implementation. The following study presents a scalable, technology-driven solution to address existing challenges and foster sustainable growth and competitiveness in Bangladesh’s heavy industries. Overall, the framework offers a scalable, technology-driven solution that supports sustainable growth and strengthens the global competitiveness of Bangladesh’s heavy industries, while aligning with the broader vision of industrial digital transformation.

Keywords

Digital Twin, Lean Manufacturing, Predictive Maintenance, Process Improvement, Steel Industry. 

Biographies
Quazi Monjur E-Elahi is a graduate student of Industrial and Production Engineering (IPE) under the Department of Mechanical and Production Engineering (MPE) at the Ahsanullah University of Science and Technology (AUST). He is currently pursuing his Master's degree in Advanced Engineering Management (AEM) under the Department of Industrial & Production Engineering (IPE) at Bangladesh University of Engineering and Technology (BUET). His research interests include the area of Industrial Management, Engineering Management, Supply Chain Management, Quality Assurance & Control, Production Planning and Control, Project & Quality Management, Productivity Engineering, Industrial & Business Management, Advanced Material Processes, Lean Manufacturing, Technology Management and Industry 4.0. He has vast experience in content writing and research, documentation management process, content research, team management. He has proficiency in Microsoft Word and Excel. He is also focused in the research of the aerospace industry and wants to work within such an industry. He also participated in a multiple number of engineering competitions showcasing his ability to solve complex problems and work collaboratively in a team with effective leadership. He was also the former Vice President of IEOM Society AUST Student Chapter. He was also the former Chief Advisor & President of Josephite Chess Club. He is currently serving as an Administrative Marketing Staff at Timedoor Academy (Bangladesh).

Ridika Islam is an undergraduate student of Industrial and Production Engineering (IPE) under the Department of Mechanical and Production Engineering (MPE) at the Ahsanullah University of Science and Technology (AUST). Her research interests include Supply Chain Management, Blockchain Development, Industry 4.0, Web 3.0, and Lean Manufacturing. In addition to her research pursuits, she demonstrates a keen enthusiasm for digital marketing, Python programming. She has proficiency in Microsoft Word and Excel. She served as the Sub-Executive of the AUST Research and Publication Club. She currently holds the position of Treasurer for the IEOM Society AUST Student Chapter.

Umme Ayesha Rahman is an undergraduate student of Computer Science and Engineering (CSE) at the Ahsanullah University of Science and Technology (AUST). Her research interests include Supply Chain Management, Machine Learning, NLP, Industry 4.0 to name a few. In addition to her research pursuits, she demonstrates a keen enthusiasm for SQL, Data mining, C-programming, HTML, CSS, Java programming. In addition to her research pursuits, she demonstrates a keen enthusiasm for technical writing and academic documentation using Microsoft Word, LaTeX, and Excel. Beyond her academic and technical pursuits, she is a executive member of the AUST Robotics Club. Previously, she was an active member of the Viqarunnisa Noon School & College Earth Club and English Language Club.

Jubayda Sultana Sezeel is a newly graduate student of Industrial and Production Engineering (IPE) under the Department of Mechanical and Production Engineering (MPE) at the Ahsanullah University of Science and Technology (AUST). Her academic and professional interests span Supply Chain Management, Operations, Project Management, and Smart City Innovations, with a strong focus on sustainable and technology-driven solutions. Her research projects include nanosatellite technology for environmental monitoring and urban digital twin applications for smart cities. She is proficient in Microsoft Office (Word, Excel, PowerPoint), Google Suites, SolidWorks, MATLAB, and Power BI. She has also participated in multiple national and international case competitions, securing recognition as a finalist and winner. Beyond academics, she has demonstrated leadership through her roles as President of the IEOM Society AUST Student Chapter and General Secretary of the AUST Career Development Club. She has also represented global brands, serving as a Talent Ambassador for BAT Bangladesh and a Campus Ambassador for Coca-Cola CCI Bangladesh. She is currently serving as a Student Work Placement Intern in Operational Services at HSBC Bangladesh.
 

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