Learning factories represent a realistic manufacturing environment for
education
Education is a purposeful activity directed at achieving certain aims, such as transmitting knowledge or fostering skills and character traits. These aims may include the development of understanding, rationality, kindness, and honesty. Va ...
,
training
Training is teaching, or developing in oneself or others, any skills and knowledge or Physical fitness, fitness that relate to specific practicality, useful Competence (human resources), competencies. Training has specific goals of improving on ...
, and
research
Research is "creativity, creative and systematic work undertaken to increase the stock of knowledge". It involves the collection, organization and analysis of evidence to increase understanding of a topic, characterized by a particular att ...
. In the last decades, numerous learning factories have been built in academia and industry.
Definition
The term learning factory consists of two words. The word ‘
learning
Learning is the process of acquiring new understanding, knowledge, behaviors, skills, value (personal and cultural), values, attitudes, and preferences. The ability to learn is possessed by humans, animals, and some machine learning, machines ...
’ indicates the development of
competencies, while the word ‘
factory
A factory, manufacturing plant or a production plant is an industrial facility, often a complex consisting of several buildings filled with machinery, where workers manufacture items or operate machines which process each item into another. T ...
’ defines a realistic manufacturing environment. The generally accepted definition was agreed within the CIRP CWG and published in the CIRP Encyclopedia: According to the
International Academy for Production Engineering (CIRP) a learning factory is defined by
*
process
A process is a series or set of activities that interact to produce a result; it may occur once-only or be recurrent or periodic.
Things called a process include:
Business and management
*Business process, activities that produce a specific se ...
es that are authentic, include multiple stations, and comprise technical as well as organizational aspects,
* a setting that is changeable resembles a
real value chain,
* a physical
product
Product may refer to:
Business
* Product (business), an item that serves as a solution to a specific consumer problem.
* Product (project management), a deliverable or set of deliverables that contribute to a business solution
Mathematics
* Produ ...
being manufactured, and
* a didactical concept that comprises formal, informal and non-formal learning, enabled by own actions of the trainees in an on-site learning approach.
Depending on the purpose of the learning factory, learning takes place through
teaching
Teaching is the practice implemented by a ''teacher'' aimed at transmitting skills (knowledge, know-how, and interpersonal skills) to a learner, a student, or any other audience in the context of an educational institution. Teaching is closely re ...
, training and/or
research
Research is "creativity, creative and systematic work undertaken to increase the stock of knowledge". It involves the collection, organization and analysis of evidence to increase understanding of a topic, characterized by a particular att ...
. Consequently, learning outcomes may be competency development and/or innovation. An
operating model
An operating model is both an abstract and visual representation (model) of how an organization delivers value to its customers or beneficiaries as well as how an organization actually runs itself.
Definition
There are different ways of defining t ...
ensuring the sustained operation of the learning factory is desirable.
The difference between learning factories and model factories is that learning factories provide a didactical concept and an
operating model
An operating model is both an abstract and visual representation (model) of how an organization delivers value to its customers or beneficiaries as well as how an organization actually runs itself.
Definition
There are different ways of defining t ...
for training.
History
The term ‘learning factory’ was first coined in the US in 1994, when the
National Science Foundation
The National Science Foundation (NSF) is an independent agency of the United States government that supports fundamental research and education in all the non-medical fields of science and engineering. Its medical counterpart is the National I ...
(NSF) awarded a consortium of the Penn State University. Industry-related design projects have been supported on a 2000 m² facility with machines, tools, and materials. Real problems of the industry could be solved in a realistic environment. In 2006, the program received the National Academy of Engineering’s Gordon Prize for Innovation in Engineering Education. In Europe, more and more learning factories have been designed in the last decade. One of the first learning factories in this wave is the ‘Center for industrial Productivity’ founded by the Institute for Production Management, Technology and Machine Tools (Technische Universität Darmstadt), established in 2007 (see section 3).
In 2011, the Initiative on ‘European Learning Factories’ was established with the 1st Conference on Learning Factories in Darmstadt (Germany).
The Initiative has led to a European collaboration on the topic of learning factories. In 2017, the initiative decided to include learning factories from all continents and renamed itself to the ‘International Association of Learning Factories’.
Examples of existing learning factories
Learning factories in academia
TU Darmstadt: Process Learning Factory CiP
In the Process Learning Factory CiP of the
Technische Universität Darmstadt
The Technische Universität Darmstadt (official English name Technical University of Darmstadt, sometimes also referred to as Darmstadt University of Technology), commonly known as TU Darmstadt, is a research university in the city of Darmstadt ...
focuses on developing competencies for
lean production
Lean manufacturing is a production method aimed primarily at reducing times within the production system as well as response times from suppliers and to customers. It is closely related to another concept called just-in-time manufacturing (J ...
and
Industrie 4.0. It has been established in 2007. The delivery of raw material, machining, quality control, assembly, packing, and indirect processes are simulated similar to
a small and medium-sized enterprise . Besides the eight variants of the
pneumatic cylinder
Pneumatic cylinders (sometimes known as air cylinders) are mechanical devices which use the power of compressed gas to produce a force in a reciprocating linear motion.
Like hydraulic cylinders, something forces a piston to move in the desire ...
, customer-individualized requirements of different measurements are implemented in a lean machining area. On about 500 m², learners apply lean methods and solve problems on own experience. The learning factory can map different scenarios from a wasteful and unbalanced production environment to a lean and a digital lean state. The 15 different learning modules are structured in lean basics, lean core elements and lean thinking. Within a learning module, practical experiences alternate with theoretical teaching. The Process Learning Factory CiP is a part of the SME competency center for the Rhine-Main area funded by the German Federal Ministry for Economic Affairs and Energy. With new implemented Industrie 4.0-technologies the concept of lean is extended. Different technologies are implemented, e.g. product traceability, worker assistance, digital shopfloor management, predictive maintenance, milk run 4.0 and AGVs. With each implemented technology new topics for the learning modules are integrated. Furthermore, the operating institute has established many learning factories for academia and industry worldwide.
Technische Universität Wien: Pilot Factory
In the
TU Wien
TU Wien (TUW; german: Technische Universität Wien; still known in English as the Vienna University of Technology from 1975–2014) is one of the major universities in Vienna, Austria. The university finds high international and domestic recogn ...
Pilot Factory focuses on Industrie 4.0. It is a realistic test environment with real machines, real production chains, and a real product. On 900 m² a 3D printer is produced that uses the principle of fused deposition modeling. The printer dimensions can be configured on customer requirements. Different Industrie 4.0-concepts are integrated, e.g. process and layout adaptivity, a high degree of human-machine interaction, and use of data analytics for transparency and optimization. AGV transportation connects the manufacturing with the assembly area. The material is replenished automatically. Furthermore, operators are assisted with collaborative robots, assistance systems, sensor technology, and image processing.
Stellenbosch University: Stellenbosch Learning Factory
The Stellenbosch Learning Factory of the
Stellenbosch University
Stellenbosch University ( af, Universiteit Stellenbosch) is a public research university situated in Stellenbosch, a town in the Western Cape province of South Africa. Stellenbosch is the oldest university in South Africa and the oldest extant ...
provides trainings for lean operations, ergonomics and is a research platform for Industrie 4.0. The target groups are industry partners and students for industrial engineering. New developments include a double degree M.Sc. Program with the
Reutlingen University
__FORCETOC__
Reutlingen University (in German ''Hochschule Reutlingen''; formerly ''FHTW Reutlingen'') is a university of applied sciences, involved in education and research. It is located in Reutlingen in the southern German state of Baden-Wür ...
. German students have the possibility to visit a summer school. In the learning factory a RFID track and trace-system and a real time KPI visualization are integrated. The product of the Stellenbosch University is a O-scale train set.
University of Windsor: iFactory
The iFactory of the
University of Windsor
, mottoeng = Goodness, Discipline and Knowledge
, established =
, academic_affiliations = CARL, COU, Universities Canada
, former_names = Assumption College (1857-1956)Assumption University of Windsor (1956-1963)
, type = Public universit ...
has the main topics integrated product – systems learning and Industrie 4.0. Desksets and automobile belt tensioners are assembled on 200 sqm. The tracking of processes and production operations planning and scheduling is possible with RFID tags. The complete system is modular and reconfigurable with equipment from FESTO Didactic. The main purpose of the learning factory is research, teaching and demonstration for students and industry. The learning factory was set up in 2011 and is the first of its kind in North America.
Université du Luxembourg: Operational Excellence Laboratory
The Operational Excellence Laboratory of the Université du Luxembourg is place for industrial partners to get hands-on experience of lean tools and demonstrate new technology related to Industrie 4.0. Examples for new technologies are the integration of RFID, augmented reality and digital manuals. Furthermore engineering master students are trained. The learning factory is a platform for retrofitting new technological features to develop, analyze and validate their usability in assembly or disasssembly lines. The product of the learning factory is a hole puncher.
Technische Universität München: Learning Factory for Lean Production (LSP)
The focus of the Learning Factory for Lean production (LSP) at the
TU München
The Technical University of Munich (TUM or TU Munich; german: Technische Universität München) is a public research university in Munich, Germany. It specializes in engineering, technology, medicine, and applied and natural sciences.
Establis ...
is lean production. The manufactured product is a real gearbox with 24 variants. The facility consists of an assembly area, a kaizen workshop area, and a theoretical teaching area. The processes logistics, assembly, quality control and packaging are mapped. A typical lean journey is recreated during the course: from an unsatisfying situation to a lean state. The theory is taught in theory lessons slots. Four to six trainings are offered every year. The mobile equipment can be transported to any location.
Ruhr-Universität Bochum: LPS Learning Factory
The main topics of the LPS Learning Factory are lean production, Industrie 4.0 and resource efficiency. It was established in 2009 by the
Ruhr Universität Bochum
The Ruhr University Bochum (, ) is a public research university located in the southern hills of the central Ruhr area, Bochum, Germany. It was founded in 1962 as the first new public university in Germany after World War II. Instruction began in ...
. Bottle caps, bottle cap holders and various make-to-order products are manufactured on 1800 m². The production environment includes various machine tools, load transports, manual assembly stations, and various industrial robots. The main topics are lean production, Industrie 4.0 and resource efficiency. Every year 900 students are practicing exercises. Real products that are purchased for the industry are produced. Besides that, numerous research projects take place in the learning factory, e.g. Industrie 4.0 maturity model, assistance and learning systems, cyber-physical production systems and industrial robotics. Since 2018 the learning factory is part of the SME 4.0 competence center Siegen.
Hochschule Reutlingen: Werk150
Th
Werk150(formerly ESB Logistics Learning Factory) at
ESB Business School
The ESB Business School (formerly ''ESB Reutlingen'') is Reutlingen University's business school founded in 1971 and based in Baden-Württemberg, Germany. Since 2008, the school is responsible for all business and production management related deg ...
is an authentic learning, development and research environment. The facility, which was started in 2014, provides a cutting-edge infrastructure for the training and advanced training of students. Moreover, topical issues of applied research are also addressed, and new methods, tools and future technologies as well as control methods for adaptable work and logistics systems are developed and tested. The results of the applied research are continuously integrated in the course activities. The Werk150 images a model production company with its entire industrial value chain and a changing product and services portfolio. Especially processes in the areas of product and work system engineering, incoming goods, storage, order picking, production, assembly and additive manufacturing as well as distribution are replicated and looked at in their entirety.
In the Werk150 the requirements and influences from Industry 4.0 are investigated and conveyed in teaching and further training courses. It has a digital twin or image that is linked with a real factory using information and communication technologies. Thus, both products and production can be planned and simulated virtually, production controlled digitally and the status and localisation of orders, parts and resources monitored in real time.
Learning factories in industry
MPS Lernplattform
Since 2011, the MPS Lernplattform of the
Daimler AG
The Mercedes-Benz Group AG (previously named Daimler-Benz, DaimlerChrysler and Daimler) is a German multinational automotive corporation headquartered in Stuttgart, Baden-Württemberg, Germany. It is one of the world's leading car manufacture ...
manufactures different products on 3000 m² with the main topic of lean production. The original components of the production as well as 1:10 models with several simulations are used. A press shop, body shop, paint shop, assembly and logistics as parts of the automobile industry are simulated. The assembled products can be reused after the training: e.g. roof control units, sun visors, covers, floor mats or room tears. Qualified in-house employees carry out the training who have didactical background knowledge as well as long-term experience in the production area. The training consists of 20% theory and 80% practice. More than ten different learning modules are offered for participants who take important insights to their daily work. The MPS Lernplattform increasingly relies on cooperation with external partners such as the TU Darmstadt.
Festo Learning Factory Scharnhausen
The Festo Learning Factory in Scharnhausen is operated by
Festo AG since 2014 with four different topics: mechanical processing (1), valve and valve terminal assembly (2), automation and process improvement (4), administration of the learning factory (4). Pneumatic valves and valve terminals are manufactured on 220 m² on four rooms. More than forty learning modules are offered on fourteen different workplaces. The participants are exclusively from Festo, especially for the training of new operators and advanced qualification of incumbent workers. Each team leader or a qualified team specialist trains the operators by themselves. Therefore ‘Train-the-trainer’-modules have been developed. The trainings are developed continuously. New products, new processes, new production equipment are integrated.
Approach to Competency-Oriented Planning and Design
The concept of learning factories offers potentials to former didactical and technical approaches. Through the realistic environment, learners are more motivated and the development of competencies facilitates.
Problem-based,
project-based or research-based learning is possible. Action-oriented learning results in significant advantages compared to traditional teaching methods. Methods, innovations, and technologies can be transferred to the industry more easily. Through learning factories learners can apply methods on a realistic production environment without the negative effect of stopping production lines in their own enterprise.
Learning Factories are designed on three design levels:
* In the macro level, the complete educational program and the physical factory environment with the factory elements are designed. It includes the social-technical infrastructure (the production environment, production processes, the product, and the employees). In the design process the learning goals, target groups, and other stakeholders are to be included.
* The different learning modules are designed at the meso level. Each learning modules can use different parts of the learning factory environment. The learning process should be structured in this design level.
* The micro level focuses on the learning scenarios within a learning module. The learning scenarios are classified in exploratory, experimental, systematizing or reflective parts. The learning objectives determine the learning scenario. The preparation of the learning factory itself should be considered in this design level as well as the learning support, learning material, learning medium and the learning product.
More details about the
design process
A design is a plan or specification for the construction of an object or system or for the implementation of an activity or process or the result of that plan or specification in the form of a prototype, product, or process. The verb ''to design'' ...
of learning factories can be seen in the dissertation of Michael Tisch with the title “Modellbasierte Methodik zur kompetenzorientierten Gestaltung von Lernfabriken für die schlanke Produktion”.
Limitations of learning factories
The learning factory concept is also limited. The planning, development, construction, and operation of learning factories require financial and personnel resources. Physical learning factories need space in a facility. Machines, workplaces, and other factory elements must be purchased and maintained. Partners and personnel should be willing and able to participate in a learning factory. The sustainability must be ensured through an operating model. Furthermore, learning factories map limited sections of production environments. A single learning factory is not able to provide a suitable, general environment for all challenges in academia and industry. Specific industrial sectors, addressed topics, single production processes, company departments, and target groups are addressed. The mapping abilities of learning factories are limited.
See also
*
Manufacturing
Manufacturing is the creation or production of goods with the help of equipment, labor, machines, tools, and chemical or biological processing or formulation. It is the essence of secondary sector of the economy. The term may refer to a r ...
*
Lean Production
Lean manufacturing is a production method aimed primarily at reducing times within the production system as well as response times from suppliers and to customers. It is closely related to another concept called just-in-time manufacturing (J ...
*
Competency
*
Industrie 4.0
References
External links
International Association of Learning FactoriesProcess Learning Factory CiP
{{DEFAULTSORT:Learning Factory
Learning
Lean manufacturing
Fourth Industrial Revolution