immersive virtual reality simulation deployment in a lean manufacturing environment

Immersive Virtual Reality Simulation Deployment In A

Lean Manufacturing Environment

Adam Gamlin

Oct 2014

Adam Daniel Gamlin ITAG14 Immersive Virtual Reality Simulation Deployment In a Lean Manufacturing Environment

Introduction

• Collaboration between NTU and PepsiCo

Walkers.

• To create a Simulation ultilising modern

Virtual Reality technologies.

• To promote Lean thinking in the workplace.

• Demonstrate the Man/Machine Interaction.

• MSc Major Project involved the use of C#

and JS in Unity3D.


Lean

Lean Methodology

“Anything other than the creation of value for the customer is seen to be wasteful and sought to be reduced

upon and ultimately eliminated.” [1]

Lean Waste Management

Transport, Inventory, Motion, Waiting, Over Processing, Over Production, Defects.

A Manufacturing Methodology which stems from the

Toyota Production System in post World War II Japan.

The elimination of Muda known as waste was key

to their success in becomming the world largest Car

manufacturer today.

[1] Gamlin, A., 2014. Immersive Virtual Reality Simulation Deployment in a Lean

Manufacturing Environment. Nottingham, ITAG.

[2]http://totalqual itymanagement.wordpress.com/2008/10/28/lean-

production-system/

[2] Toyota Production System (TPS)


Virtual Reality Technology

• Written in C# and Java Script through Unity3D

• Two Simulations were designed and created:

-Learning Based Simulation using the Oculus

Rift Development Kit 2.

-Machinery Layout Design Simulation using the

zSpace Virtual Reality Screen.

The Learning Simulation incorporates the proposed

Machine GUI, Xbox Controller Support and Fly/

Walk Controls to immerse the user in operating new

machinery before it has been built and assembled.

The Design Simulation allows the user to assemble

manufacturing cells and create worker travel paths in

the proposed manufacturing environment.


Game Based Learning

Visual Affordance through Semiotics

Tactical Immersion

Strategic Immersion

Narrative Immersion

Instructional Scaffolds

Control Acessibility

“The reason video games have become so

successful in acquiring the largest share in an

extremely competitive market is because they

effectively teach players how to play the game” [3]

[3] Wainess, R., Koenig, A. & Kerr, D., 2011. Alligning Instruction

and Assesment with Game and Simulation Design, Los Angeles:

CRESST.


Learning Simulation


Design Simulation


System Architecture

Lean Manufacturing Process Simulation

Learning Simulation Tool Through Narrative

& Gameplay

GUI

User

3D Model of SimulationDesign Tool for Cell Layout


Future Features

• Fully Simulated Manufacturing Plant, including the old and proposed machinery.

• Co-operative Multiplayer

• Managerial Oversight

• Problem implementation

• AI workforce


[1] Gamlin, A., 2014. Immersive Virtual Reality Simulation Deployment in a Lean

Manufacturing Environment. Nottingham, ITAG.

[4]http://www.foundationsoft.com/resources/articles/112-5-tips-to-avoid-end-

user-rejection-of-new-technology-implementation.htm

Player Objectives

“If the user can understand how to beat the simulation then the simulation has

succeeded in teaching the user how to fulfil their role in the PepsiCo

processing plant [1].”

• Operators gain a deeper understanding of thier new work cell.

• Potentially involved in the design process through feedback and user testing.

• Begin working with the new machine Graphical User Interface before it has been deployed.

• Replace online training programs with Immersive Virtual Reality Training packages

• Layout Designers obtain a more realistic understanding of form.

• Ability to simulate worker travel paths around the cell.

The user needs to be presented with realistic challenges that can occur within the real

manufacturing cell.

“In the industrial sector alone, nearly half of a company’s workforce resist technological

implementation in some way [4].”

Thankyou for your time, questions?

immersive virtual reality simulation deployment in a lean manufacturing environment

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