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1. A Virtual Learning Factory for Advanced Manufacturing

   Aqlan, Faisal; Zhao, Richard; Yang, Hui; Ramakrishnan, Sreekanth (December 2021, Proceedings of the Winter Simulation Conference)

   null (Ed.)

   Virtual reality (VR) technology allows for the creation of fully immersive environments that enable personalized manufacturing learning. This case study discusses the development of a virtual learning factory that integrates manual and automated manufacturing processes such as welding, fastening, 3D printing, painting, and automated assembly. Two versions of the virtual factory are developed: (1) a multiplayer VR environment for the design and assembly of car toys; which allows for the collaboration of multiple users in the same VR environment, and (2) a virtual plant that utilizes heavy machinery and automated assembly lines for car manufacturing. The virtual factory also includes an intelligent avatar that can interact with the users and guide them to the different sections of the plant. The virtual factory enhances the learning of advanced manufacturing concepts by combining virtual objects with hands-on activities and providing students with an engaging learning experience. 

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2. Eye-Track Modeling of Problem-Solving in Virtual Manufacturing Environments

   Zhu, Rui; Aqlan, Faisal; Zhao, Richard; Yang, Hui (July 2021, ASEE annual conference proceedings)

   null (Ed.)

   Problem-solving focuses on defining and analyzing problems, then finding viable solutions through an iterative process that requires brainstorming and understanding of what is known and what is unknown in the problem space. With rapid changes of economic landscape in the United States, new types of jobs emerge when new industries are created. Employers report that problem-solving is the most important skill they are looking for in job applicants. However, there are major concerns about the lack of problem-solving skills in engineering students. This lack of problem-solving skills calls for an approach to measure and enhance these skills. In this research, we propose to understand and improve problem-solving skills in engineering education by integrating eye-tracking sensing with virtual reality (VR) manufacturing. First, we simulate a manufacturing system in a VR game environment that we call a VR learning factory. The VR learning factory is built in the Unity game engine with the HTC Vive VR system for navigation and motion tracking. The headset is custom-fitted with Tobii eye-tracking technology, allowing the system to identify the coordinates and objects that a user is looking at, at any given time during the simulation. In the environment, engineering students can see through the headset a virtual manufacturing environment composed of a series of workstations and are able to interact with workpieces in the virtual environment. For example, a student can pick up virtual plastic bricks and assemble them together using the wireless controller in hand. Second, engineering students are asked to design and assemble car toys that satisfy predefined customer requirements while minimizing the total cost of production. Third, data-driven models are developed to analyze eye-movement patterns of engineering students. For instance, problem-solving skills are measured by the extent to which the eye-movement patterns of engineering students are similar to the pattern of a subject matter expert (SME), an ideal person who sets the expert criterion for the car toy assembly process. Benchmark experiments are conducted with a comprehensive measure of performance metrics such as cycle time, the number of station switches, weight, price, and quality of car toys. Experimental results show that eye-tracking modeling is efficient and effective to measure problem-solving skills of engineering students. The proposed VR learning factory was integrated into undergraduate manufacturing courses to enhance student learning and problem-solving skills. 

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3. Multiplayer Physical and Virtual Reality Games for Team-based Manufacturing Simulation

   Aqlan, F. (June 2020, ASEE Annual Conference proceedings)

   Familiarity with manufacturing environments is an essential aspect for many engineering students. However, such environments in real world often contain expensive equipment making them difficult to recreate in an educational setting. For this reason, simulated physical environments where the process is approximated using scaled-down representations are usually used in education. However, such physical simulations alone may not capture all the details of a real environment. Virtual reality (VR) technology nowadays allows for the creation of fully immersive environments, bringing simulations to the next level. Using rapidly advancing gaming technology, this research paper explores the applicability of creating multiplayer serious games for manufacturing simulation. First, we create and validate a hands-on activity that engages groups of students in the design and assembly of toy cars. Then, a corresponding multiplayer VR game is developed, which allows for the collaboration of multiple VR users in the same virtual environment. With a VR headset and proper infrastructure, a user can participate in a simulation game from any location. This paper explores whether multiplayer VR simulations could be used as an alternative to physical simulations. 

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4. Multiplayer Physical and Virtual Reality Games for Team-based Manufacturing Simulation

   https://doi.org/10.18260/1-2--34989  

   Zhao, R.; Aqlan, F.; Elliott, L.; Baxter, E. (June 2020, ASEE Annual Conference proceedings)

   Familiarity with manufacturing environments is an essential aspect for many engineering students. However, such environments in real world often contain expensive equipment making them difficult to recreate in an educational setting. For this reason, simulated physical environments where the process is approximated using scaled-down representations are usually used in education. However, such physical simulations alone may not capture all the details of a real environment. Virtual reality (VR) technology nowadays allows for the creation of fully immersive environments, bringing simulations to the next level. Using rapidly advancing gaming technology, this research paper explores the applicability of creating multiplayer serious games for manufacturing simulation. First, we create and validate a hands-on activity that engages groups of students in the design and assembly of toy cars. Then, a corresponding multiplayer VR game is developed, which allows for the collaboration of multiple VR users in the same virtual environment. With a VR headset and proper infrastructure, a user can participate in a simulation game from any location. This paper explores whether multiplayer VR simulations could be used as an alternative to physical simulations. 

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5. Towards Smart Manufacturing Metaverse via Digital Twinning in Extended Reality

   https://doi.org/10.1115/1.4070437  

   Yang, Hui; Aqlan, Faisal; Zhao, Richard (November 2025, Journal of Computing and Information Science in Engineering)

   The rapid evolution of modern manufacturing systems is driven by the integration of emerging metaverse technologies such as artificial intelligence (AI), digital twin (DT), and different forms of extended reality (XR) like virtual reality (VR), augmented reality (AR), and mixed reality (MR). These advances confront manufacturing workers with complex and evolving environments that demand digital literacy for problem solving in the future workplace. However, manufacturing industry faces a critical shortage of skilled workforce with digital literacy in the world. Further, global pandemic has significantly changed how people work and collaborate digitally and remotely. There is an urgent need to rethink digital platformization and leverage emerging technologies to propel industrial evolution toward human-centered manufacturing metaverse (MfgVerse). This paper presents a forward-looking perspective on the development of MfgVerse, highlighting current efforts in learning factory, cognitive digital twinning, and the new sharing economy of manufacturing-as-a-service (MaaS). MfgVerse is converging into multiplex networks, including a social network of human stakeholders, an interconnected network of manufacturing things or agents (e.g., machines, robots, facilities, material handling systems), a network of digital twins of physical things, as well as auxiliary networks of sales, supply chain, logistics, and remanufacturing systems. We also showcase the design and development of a virtual learning factory for workforce training. Finally, future directions, challenges, and opportunities are discussed for human-centered manufacturing metaverse. We hope this work helps stimulate more comprehensive studies and in-depth research efforts to advance MfgVerse technologies. 

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