Skip to main content
SpringerLink
Log in

Effect of Virtual Reality-Based Training on Complex Industrial Assembly Task Performance

  • Research Article-Mechanical Engineering
  • Published:
Arabian Journal for Science and Engineering Aims and scope Submit manuscript

Abstract

This study investigates the effect and permanency of a virtual reality (VR) based training method on complex assembly task performance and product quality. The correct assembly of a complex industrial product is crucial to reduce the production flaw in manufacturing. For this reason, a VR training set was developed for a hydraulically-controlled clutch complete set (HCCCS), consisting of 90 parts, to investigate the effectiveness and permanency of assembly training. A highly reliable measurement tool (KR-20 = 0.81) was developed to measure the participants’ assembly task performance for this study. Two different experimental designs were used to firmly control threats to internal validity, such as testing, subject characteristics, maturation, and regression. One hundred and twelve factory workers who had no VR and assembly experience were assigned to the randomized post-test-only control group design (n = 56) and the randomized pre-test/post-test control group design using matched subjects (n = 56). In addition, training permanency was investigated, and the HCCCS quality reports were monitored every month for 6 months. The study results revealed that the VR-based training method reduced the training time per individual by 25% and achieved a 27.9% improvement in complex industrial assembly task performance. The quality reports also showed that the HCCCS assembly flaw rate was reduced by 89% and maintained the permanency of the VR-based training in complex industrial maintenance and assembly (IMA) tasks.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4

Similar content being viewed by others

References

  1. Dickey, M.D.: Three-dimensional virtual worlds and distance learning: two case studies of Active Worlds as a medium for distance education. Blackwell Publishing Ltd (2005)

  2. Wolfartsberger, J.: Analyzing the potential of virtual reality for engineering design review. Autom. Constr. 104, 27–37 (2019). https://doi.org/10.1016/j.autcon.2019.03.018

    Article  Google Scholar 

  3. Jensen, L.; Konradsen, F.: A review of the use of virtual reality head-mounted displays in education and training. Educ. Inf. Technol. 23, 1515–1529 (2018). https://doi.org/10.1007/s10639-017-9676-0

    Article  Google Scholar 

  4. Aziz, F.A.;Alshammar, M.;Ariffin, M.K.A.: Using virtual reality for equipment maintenance in oil and gas industry, (2018)

  5. Perez-Ramirez, M.; Arroyo-Figueroa, G.; Ayala, A.: The use of a virtual reality training system to improve technical skill in the maintenance of live-line power distribution networks. Interact. Learn. Environ. (2019). https://doi.org/10.1080/10494820.2019.1587636

    Article  Google Scholar 

  6. Otto, M.; Lampen, E.; Agethen, P.; Langohr, M.; Zachmann, G.; Rukzio, E.: A virtual reality assembly assessment benchmark for measuring VR performance & limitations. Procedia CIRP. 81, 785–790 (2019). https://doi.org/10.1016/j.procir.2019.03.195

    Article  Google Scholar 

  7. Shamsuzzoha, A.; Toshev, R.; Vu Tuan, V.; Kankaanpaa, T.; Helo, P.: Digital factory–virtual reality environments for industrial training and maintenance. Interact. Learn. Environ. (2019). https://doi.org/10.1080/10494820.2019.1628072

    Article  Google Scholar 

  8. Sekaran, S.C.; Yap, H.J.; Liew, K.E.; Kamaruzzaman, H.; Tan, C.H.; Rajab, R.S.: Haptic-based virtual reality system to enhance actual aerospace composite panel drilling training. In: Structural Health Monitoring of Biocomposites, Fibre-Reinforced Composites and Hybrid Composites. pp. 113–128. Elsevier (2018)

  9. Eschen, H.; Kötter, T.; Rodeck, R.; Harnisch, M.; Schüppstuhl, T.: Augmented and virtual reality for inspection and maintenance processes in the aviation industry. Procedia Manuf. 19, 156–163 (2018). https://doi.org/10.1016/j.promfg.2018.01.022

    Article  Google Scholar 

  10. Zhou, L.; Xue, Q.; Sun, J.; Liu, S.; Xie, X.; Zhang, Q.: The maintenance evaluation method based on virtual reality. In: Proceeding of the 24th International Conference on Industrial Engineering and Engineering Management 2018. pp. 209–216. Springer Singapore (2019)

  11. Channarong, T.; Suthep, B.: Virtual reality barrel shaft design and assembly planning accompany with CAM. Procedia Manuf. 30, 677–684 (2019). https://doi.org/10.1016/j.promfg.2019.02.063

    Article  Google Scholar 

  12. Vosniakos, G.C.; Deville, J.; Matsas, E.: On Immersive virtual environments for assessing human-driven assembly of large mechanical parts. Procedia Manuf. 11, 1263–1270 (2017). https://doi.org/10.1016/j.promfg.2017.07.253

    Article  Google Scholar 

  13. Meunier, L.; Keller, D.; Guédon, P.: Virtual reality: lessons learned from WEST design and perspectives for nuclear environment. Fusion Eng. Des. 136, 1337–1341 (2018). https://doi.org/10.1016/j.fusengdes.2018.05.004

    Article  Google Scholar 

  14. Guo, Z.; Zhou, D.; Zhou, Q.; Zhang, X.; Geng, J.; Zeng, S.; Lv, C.; Hao, A.: Applications of virtual reality in maintenance during the industrial product lifecycle: A systematic review. J. Manuf. Syst. 56, 525–538 (2020). https://doi.org/10.1016/j.jmsy.2020.07.007

    Article  Google Scholar 

  15. Gavish, N.; Gutiérrez, T.; Webel, S.; Rodríguez, J.; Peveri, M.; Bockholt, U.; Tecchia, F.: Evaluating virtual reality and augmented reality training for industrial maintenance and assembly tasks. Interact. Learn. Environ. 23, 778–798 (2015). https://doi.org/10.1080/10494820.2013.815221

    Article  Google Scholar 

  16. Abidi, M.H.; Al-Ahmari, A.; Ahmad, A.; Ameen, W.; Alkhalefah, H.: Assessment of virtual reality-based manufacturing assembly training system. Int. J. Adv. Manuf. Technol. 105, 3743–3759 (2019). https://doi.org/10.1007/s00170-019-03801-3

    Article  Google Scholar 

  17. Langley, A.; Lawson, G.; Hermawati, S.; D’Cruz, M.; Apold, J.; Arlt, F.; Mura, K.: Establishing the usability of a virtual training system for assembly operations within the automotive industry. Hum. Factors Ergon. Manuf. 26, 667–679 (2016). https://doi.org/10.1002/hfm.20406

    Article  Google Scholar 

  18. Sportillo, D., Avveduto, G., Tecchia, F., Carrozzino, M.: Training in VR: A preliminary study on learning assembly/disassembly sequences. Lect. Notes Comput. Sci. (including Subser. Lect. Notes Artif. Intell. Lect. Notes Bioinformatics). 9254, 332–343 (2015). https://doi.org/10.1007/978-3-319-22888-4_24

  19. Kaplan, A.D.; Cruit, J.; Endsley, M.; Beers, S.M.; Sawyer, B.D.; Hancock, P.A.: The effects of virtual reality, augmented reality, and mixed reality as training enhancement methods: A meta-analysis. Hum. Factors. (2020). https://doi.org/10.1177/0018720820904229

    Article  Google Scholar 

  20. Merchant, Z.; Goetz, E.T.; Cifuentes, L.; Keeney-Kennicutt, W.; Davis, T.J.: Effectiveness of virtual reality-based instruction on students’ learning outcomes in K-12 and higher education: A meta-analysis. Comput. Educ. 70, 29–40 (2014). https://doi.org/10.1016/j.compedu.2013.07.033

    Article  Google Scholar 

  21. Lanier, M.; Waddell, T.F.; Elson, M.; Tamul, D.J.; Ivory, J.D.; Przybylski, A.: Virtual reality check: Statistical power, reported results, and the validity of research on the psychology of virtual reality and immersive environments. Comput. Human Behav. 100, 70–78 (2019). https://doi.org/10.1016/j.chb.2019.06.015

    Article  Google Scholar 

  22. Longo, F.; Nicoletti, L.; Padovano, A.: Smart operators in industry 4.0: A human-centered approach to enhance operators’ capabilities and competencies within the new smart factory context. Comput. Ind. Eng. 113, 144–159 (2017). https://doi.org/10.1016/j.cie.2017.09.016

  23. El Maniani, M.; Rechchach, M.; El Mahfoudi, A.; El Moudane, M.; Sabbar, A.: A Calorimetric investigation of the liquid bi-ni alloys. J. Mater. Environ. Sci. 7, 3759–3766 (2016)

    Google Scholar 

  24. Jarmon, L.; Traphagan, T.; Mayrath, M.; Trivedi, A.: Virtual world teaching, experiential learning, and assessment: An interdisciplinary communication course in Second Life. Comput. Educ. 53, 169–182 (2009). https://doi.org/10.1016/j.compedu.2009.01.010

    Article  Google Scholar 

  25. Zawadzki, P.; Buń, P.; Górski, F.: Virtual reality training of practical skills in industry on example of forklift operation. Lect. Notes Electr. Eng. 505, 46–52 (2019). https://doi.org/10.1007/978-3-319-91334-6_7

    Article  Google Scholar 

  26. Sebok, A.; Nystad, E.; Drøivoldsmo, A.: Improving safety and human performance in maintenance and outage planning through virtual reality-based training systems. In: IEEE Conference on Human Factors and Power Plants. pp. 814–822 (2002)

Download references

Acknowledgements

The authors thank TürkTraktör and its authorities for providing all opportunities to conduct this research. Special thanks to senior training specialist Orhan Yazkan, senior supervisors Ceyhun Bilecen, and Serdal Yaviç, who provided their valuable support in all the study steps. The authors would like to express special thanks to Prof Vesile Alkan for constructive criticism of the manuscript. Finally, we declare that a part of this study was presented as an oral abstract presentation at the II. International Conference on Distance Learning and Innovative Educational Technologies (DILET 2018) held on 13 December 2018 in Ankara, Turkey.

Funding

This work was supported by the Erasmus + Program of the European Union under grant number 2017–1-TR01-KA202-046646. However, the European Commission and the Turkish National Agency cannot be held responsible for any use that may be made of the information contained herein.

Author information

Authors and Affiliations

  1. Educational Measurement and Evaluation Department, Faculty of Education, Pamukkale University, 20160, Denizli, Turkey

    Ömür Kaya Kalkan

  2. Department of Mechanical Program, Hacettepe University, 06935, Ankara, Turkey

    Şener Karabulut

  3. TurkTraktor and Agricultural Machinery, Inc, 06560, Ankara, Turkey

    Gürhan Höke

Authors
  1. Ömür Kaya Kalkan
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Şener Karabulut
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Gürhan Höke
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Şener Karabulut.

Ethics declarations

Competing interest

The authors declare no competing interests.

Ethical approval

Authors remained loyal to ethical rules during the data collection process.

Consent to participate

All authors have consented to participate in this study.

Consent to publish

All authors have consented to the publication of this work.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Kalkan, Ö.K., Karabulut, Ş. & Höke, G. Effect of Virtual Reality-Based Training on Complex Industrial Assembly Task Performance. Arab J Sci Eng 46, 12697–12708 (2021). https://doi.org/10.1007/s13369-021-06138-w

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s13369-021-06138-w

Keywords

Search

Navigation