Immersive Virtual Reality Simulation Deployment in a Lean Manufacturing Environment Adam Gamlin, Philip Breedon and Benachir Medjdoub Interactive Technologies and Games (ITAG) Conference 2014 Health, Disability and Education Dates: Thursday 16 October 2014 - Friday 17 October 2014 Location: The Council House, NG1 2DT, Nottingham, UK

1. Immersive Virtual Reality Simulation Deployment In A
Lean Manufacturing Environment
Adam Gamlin
Oct 2014

2. Adam Daniel Gamlin ITAG14 Immersive Virtual Reality Simulation Deployment In a Lean Manufacturing Environment
• 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.
Introduction

3. Adam Daniel Gamlin ITAG14 Immersive Virtual Reality Simulation Deployment In a Lean Manufacturing Environment
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.
Lean
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://totalqualitymanagement.wordpress.com/2008/10/28/lean-production-
system/
[2] Toyota Production System (TPS)

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

5. Adam Daniel Gamlin ITAG14 Immersive Virtual Reality Simulation Deployment In a Lean 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.

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

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

8. Adam Daniel Gamlin ITAG14 Immersive Virtual Reality Simulation Deployment In a Lean Manufacturing Environment
Lean Manufacturing
Process Simulation
Learning Simulation
Tool Through Narrative
& Gameplay
Design Tool for Cell Layout 3D Model of Simulation
System Architecture
GUI
User

9. Adam Daniel Gamlin ITAG14 Immersive Virtual Reality Simulation Deployment In a Lean Manufacturing Environment
• Fully Simulated Manufacturing Plant, including the old and proposed machinery.
Future Features
• Co-operative Multiplayer
• Managerial Oversight
• Problem implementation
• AI workforce

10. Adam Daniel Gamlin ITAG14 Immersive Virtual Reality Simulation Deployment In a Lean Manufacturing Environment
“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].”
[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

11. Thankyou for your time, questions?