Optimization of Manufacturing Processes Using AI-Based Advisory Systems: Casting Application

Artificial Intelligence (AI) and Machine Learning (ML) are increasingly driving the digital transformation of manufacturing systems, enabling the transition from conventional process operation toward intelligent, adaptive, and data-centric production environments. This work presents the development of AI-enabled advisory systems for casting processes, integrating advanced data-driven models, reduced-order modeling techniques, and hybrid simulation frameworks to support real-time process prediction and optimization. The proposed approach leverages manufacturing data to establish predictive models capable of rapidly evaluating process conditions, optimizing operating parameters, and enhancing product quality while reducing material waste, energy consumption, and production costs. By combining physics-based understanding with AI-driven analytics, the framework facilitates real-time decision support, adaptive process control, and continuous performance improvement within modern manufacturing ecosystems. These capabilities contribute to the broader objectives of Industry 4.0 and emerging Industry 5.0 paradigms, including automation, connectivity, operational resilience, sustainability, and human-centered manufacturing. A representative industrial casting case study is presented to demonstrate the practical implementation of the framework, encompassing database generation, model training, validation, and deployment of predictive advisory tools for real-time manufacturing applications.