2025 ASEE Annual Conference & Exposition

This paper discusses the application of project-based learning (PjBL) within the context of Industry 4.0 to solve digital transformation challenges in manufacturing. Although PjBL is beginning to be recognized more widely in academic circles as the method that supports active learning through the practical application of theoretical knowledge, its effectiveness in higher education, particularly within the manufacturing sector, is underexplored. This paper fills this gap by assessing the impact of a 6-month certification program, offered to one of the world's largest steel manufacturers by a prestigious university in the country, aimed at developing critical Industry 4.0 competences for experienced manufacturing professionals lacking knowledge in digital technologies.

The curriculum for the program was developed in collaboration with industry leaders, informed by insights from on-site visits to manufacturing plants where areas of existing process pain points were identified, which guided customizable learning modules in technologies such as mechatronics, IoT, big data analytics, machine learning, and cybersecurity. It was divided into two phases of training. The foundation knowledge, through the first three months, was combined with hands-on labs and industry-relevant applications. In doing so, participants could gain actual understanding of digital technologies.

The second phase of the program transitioned participants to real-time projects from industries such as defect detection using computer vision, energy optimization, material property prediction, and IoT-based predictive maintenance. Throughout this phase, training was specialized to further assist participants in implementing projects to meet organizational requirements identified during earlier research.

The technical quality of the solutions as well as its impact on organizational performance were the technical criteria by which the program assessed participants' ability to translate theoretical knowledge into practical solutions with measurable impact. Concretely, this resulted in less machine downtime and cost savings for each project, some close to $3.5 million annually, which will be detailed in the full paper. The PjBL methodology, with its emphasis on real-time problem-solving and immediate feedback, accelerated the participants’ acquisition of digital skills and facilitated meaningful, hands-on learning experiences.

This study provides clear evidence for PjBL, particularly by the fact that critical issues facing professionals who had no prior experience with digital systems were overcome successfully through critical thinking, problem-solving, and teamwork. The authors look forward to sharing valuable insights from this study, for academic and industrial stakeholders seeking to develop workforce skills in Industry 4.0 technologies, at the ASEE 2025 conference.