A Technology Corner for Operator Training in Manufacturing Tasks

Abstract

This study is part of a project carried out in Fiat Chrysler Automobiles with the aim of introducing innovation and Industry 4.0 technologies in workers’ training. Nowadays, the training is performed using a system, called “Manufacturing Training System” (MTS), composed by three different areas: a document area in which there are step method procedures, quick kaizen and operation cards for each work phase; an ability corner with tools useful to perform activities and a simulated production line on which the operator can practice.

The iterative process with a multidisciplinary design a project was built up, keeping in mind User Center Design principles and focusing on the active engagement of the user in each design stage, to validate what actions users can be asked to perform and what tasks the system has to do automatically. In the first phase, the Cognitive Ergonomists observed and interviewed Team Leaders, workers that coordinate and manage other co-workers and know critical issues of their domain tasks. In a second phase, the so-called “personas tool” with specific characteristics and scenarios was used to analyze users’ needs. After that the new training system features were defined.

Thanks to requirement definition, four thematic areas were defined: ergonomics and safety, documents and procedures, equipment and workstation and operating procedures. For each area, the training was divided into learning and practical exercises.

Based on this approach, different tools have been chosen for each area. For example Augmented Reality was used for learning and acquiring information and notions, and Gamification Techniques were used for the practical exercises. Furthermore, storyboards were proposed as a new tool to help the learning process. Soon, mock-ups could be implemented to easily test with workers, validate project hypothesis, find critical issues and further support successful approaches.