Byron's Babbles

Yesterday I had an incredible experience at the Benteler Education and Training Center in Paderborn Germany. We had the opportunity to learn Smart Manufacturing first hand by working in the Benteler Industry 4.0 Learning Factory. This factory was built by the students and used to teach Industry 4.0 smart manufacturing practices and techniques. This learning factory also affords students the opportunity to use equipment and use 4.0 practices. There are three choices of products to build in the learning factory: speed boat, semi tractor; or sports car. The cool part was that all of the parts for the products except for the the grill ornament (made by 3D printer) were Lego™. I had the honor of working with Representative Bob Behning on this project.

The line starts with the selection of which product and what color the product will be built. For this part of the factory SMART glasses are used in order to give the student the opportunity to use and navigate this 4.0 technology. I am really glad I had the opportunity to do this. We had been hearing about SMART glasses and having the opportunity to actually use them on the production line was awesome. Then after the selection of the color and product the line gave us a tray of parts to get started.

After assembling the frame of our truck it was then moved down the assembly line and the RFID chip (I could relate to this because it is like the RFID tags we use for data and identification of our dairy cows) read what product we were building and gave us the next set of instructions digitally. As we waved our hand over the screen the proper bin for the next part would light up and then the screen told us where to put the parts. Even though we were doing some human labor on this it was evident to see all the skilled labor that was needed to program the line to give us the right parts on time during the assembly. Finally, we installed the Benteler emblem made in the 3D Printer to the grill of the truck.

One of the coolest things was at the end of the assembly line when our completed truck went into the sensors to tell us if we had made it correctly. We either got a green light or a red light. The green light meant we had it perfect, the red meant we had a flaw. Sadly, we got a read light. We went back and studied, but could not find the issue. We found there was an error and we were not given the instruction or part to put some covers on the clearance lights on the front of the truck. But, how cool is that to have sensors that could tell us if the product was perfect. Here is a picture of our final product:

I am so glad I had this experience. It also really drove home the fact that, as the research tells us, as adults we like to learn like our young students. We want the education to be relevant and we want to be engaged in the process. Let me tell you, Representative Behning and I were very engaged. We were excited as the truck came together and went down the line. Then we were screaming when the truck did not pass inspection. We were ultimately proud of our product. Bottom-line – This Industry 4.0 Learning Factory made school work into real work. We were using real life digital tools to make a real product in real time. How much more engaging can you get?

The factories of the future will be very different from the workplaces of today – in 2016 alone nearly 200,000 robots were deployed in automotive factories and a further 85,000 were installed in factories making electrical and electronic goods, so automation will liberate people from the drudgery of production lines. Now with Artificial Intelligence (AI), the robots will be able to interact with the human. These “cobots” will take robotics to a new level. This past week we have also learned that at work or at home, the Internet of Things (IoT) will completely change the way in which most of us carry out our basic daily tasks, eliminating the drudgery of shopping, banking and even cooking.

I am so glad I have had the opportunity to learn about Industry 4.0 this past week. One thing is for sure: this will completely change the dynamics of manufacturing and will mean that we will be able to make products that are tailored exactly to our wishes in every way we could want. The very same technology is already being used to produce motor vehicles and even to “print” buildings, so the possibilities are almost endless! We need to make a commitment to making sure we have our students ready for this workforce. That means we must start and continue to have the conversations between all sectors about how to do what is best for our students. This involves bringing business/industry, k-12 education, higher education, education advocate organizations, business/industry organizations, state officials, families, and students together to partner how to make this happen. I appreciate all the work that organizations like Horizon Education Alliance are already doing to make the conversations happen – thus why we are learning in Germany and Switzerland. It is the right thing to do for our scholars!