AI‐Driven Innovation in Manufacturing Digitalization: Real‐Time Predictive Models

The digital transformation of manufacturing is accelerating through the integration of artificial intelligence (AI), particularly via real-time predictive models. These models enable manufacturers to transition from reactive strategies to proactive, intelligent optimization and decision-making. Within the frameworks of Industry 4.0 and Industry 5.0, which emphasize technologies such as cyber-physical systems, cloud computing, and human-centric innovation, AI-driven data models are pivotal for achieving smart, adaptive, and sustainable production systems. This paper investigates the impact of AI-based predictive modeling on manufacturing digitalization and its future potential. It examines how these models contribute to advanced frameworks such as online pro-cess advisory systems, digital shadows, and digital twins, while addressing their limitations and implementation challenges. Furthermore, the study reviews current practices in real-time data modeling across manufacturing processes—including direct-chill casting—supported by real-world case studies. These examples illustrate both the practical benefits and technical hurdles of deploying AI in dynamic industrial environments.