In Teaching Lean Manufacturing with Digital Twin: A Modern Approach to Engineering Education

Document Type

Article

Publication Date

2026

Department

Department of Manufacturing and Mechanical Engineering Technology

Abstract

Engineering education must evolve beyond conventional classroom techniques as technology advances rapidly and Industry 4.0 practices become increasingly prevalent. This study explores integrating digital twin technology into engineering education as an innovative and effective approach to teaching lean manufacturing principles. The central research question guiding this work is: Can digital twin–based learning improve students’ understanding and application of lean manufacturing concepts compared to traditional teaching methods? A total of 40 senior-year students were surveyed, revealing an overall 63% improvement in course evaluation following the adoption of digital twin–based learning. Focusing on sensor stamping in renewable energy applications, the digital twin was developed using CAD tools such as Fusion 360 and NVIDIA Omniverse to create interactive virtual manufacturing systems. Students conducted time-motion studies, defect analyses, and production cycle optimizations through iterative simulations involving three manufacturing methods: traditional hammering, manual pressing, and automated stamping. Results demonstrated the value of design optimization and force-controlled stamping, validating the digital twin’s effectiveness in enhancing process understanding and decision-making. Overall, this study highlights the transformative potential of digital twin technology to foster experiential, data-driven learning and align engineering education with Industry 4.0 competencies.

Publication Title

Journal of Engineering Technology

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