2025 ASEE Annual Conference & Exposition

Game-Based Learning in a Manufacturing Setting to Teach Statistical Process Control

Advanced manufacturing firms wishing to adopt new digital technologies need a workforce that has the skills to collect, interpret, and analyze data. Unfortunately, many promising students who have an aptitude for work in manufacturing struggle to overcome large gaps in their math education and are missing traditional math skills required to complete data analysis courses. Students who enroll in advanced manufacturing programs often fear a repeat of ineffective math instruction lacking context or application. Game-based learning provides an opportunity to change this mindset. During standard instruction, if students cannot solve a math problem quickly, they are inclined to believe their capacity to learn data skills is inadequate and fixed in place. Simulations and digital games can directly link data skills to applications in manufacturing to solve problems on the factory floor. In games, failing before achieving a goal is not only an inherent part of the experience, but can be rewarding and satisfying. The most effective educational games are carefully scaffolded to include a combination of conceptual, procedural, and declarative knowledge development, which encourages students to move from concrete examples to generalizations and abstractions. In contrast to stand-alone math courses in data analysis and statistics, data skills integrated through a factory-floor narrative can better prepare students to transfer their knowledge to authentic manufacturing contexts.

In this work, we created simulations and learning games to help disaffected technicians and undergraduate students solve data analysis problems in the context of manufacturing. These simulations and games were integrated into a targeted series of introductory data-for-manufacturing modules. The first learning module uses a digital web/mobile game to introduce statistical process control (SPC) in a digital manufacturing environment. Over the course of four weeks, players learn to operate injection molding machines, fulfill increasingly larger orders for high-quality injection molded parts, apply SPC methods and tools to meet in-game challenges, and improve the efficiency and productivity of their manufacturing process. In between play sessions, students are provided with online learning videos, math exercises, and in-person instructor-led lab activities which are grounded in the context of the injection molding SPC game.

Authors

Dr. Erik Verlage http://orcid.org/0000-0001-5940-0859 The Ohio State University [biography]

Dr. Erik Verlage is a research scientist at The Ohio State University creating interactive simulations and learning games for workforce training in advanced manufacturing. He leads workforce education efforts at OSU's Simulation Innovation and Modeling Center (SIMCenter) and the Center for Design and Manufacturing Excellence (CDME). He founded the MIT Virtual Manufacturing Lab, where he was the lead instructor for multiple massive open online courses on integrated photonics, using application-focused learning games and micron-scale optical circuit simulations to teach photonics fundamentals.
Christian Gabbianelli Massachusetts Institute of Technology [biography]

A software developer working with realtime engines to build immersive, interactive and dynamic training simulations.
Kachina Studer Massachusetts Institute of Technology [biography]

Kachina Studer is an XR Technical Specialist at MIT, working with the Learning Engineering and Practice Group in the Department of Mechanical Engineering. Her work focuses on the development of immersive learning tools, open-ended training systems, and simulation-based environments in virtual and augmented reality. Her initiatives center on designing XR authoring platforms that enable educators and instructional designers to create flexible, skill-building experiences for manufacturing, STEM, and workforce education.
Ashim Dhakal The Ohio State University [biography]

Ashim Dhakal is a passionate Software Developer pursuing ECE at The Ohio State University, collaborating with MIT engineers to develop cutting-edge interactive simulations and immersive data visualizations. Skilled in game mechanics implementation using Unity C#, with a drive for creating seamless user experiences that bridge the gap between complex data and intuitive interfaces. Continuously exploring new technologies while refining expertise in computational problem-solving and creative coding solutions.
Mr. Zhen Zhao http://orcid.org/0009-0000-2018-5514 Massachusetts Institute of Technology [biography]

Zhen Zhao is a Postdoctoral Associate at the Massachusetts Institute of Technology. His research interests include engineering student mentorship and leadership development, engineering research center education and diversity impact evaluation, and engine
Dr. Meredith Thompson http://orcid.org/0000-0001-9989-8604 Massachusetts Institute of Technology [biography]

Meredith Thompson is a STEM education researcher and program manager for MIT's Learning Engineering And Practice (LEAP) Group. Her areas of research include virtual and augmented reality, collaboration in virtual environments, STEM education in K-16, and using simulations to prepare preservice and inservice teachers. In her current role, she is a program manager for the Technologist Advanced Manufacturing Program, or TechAMP, which aims to bridge the gap between technicians and engineers to modernize the manufacturing workforce.
Dr. John Liu http://orcid.org/0000-0002-6085-0926 Massachusetts Institute of Technology [biography]

Dr. John Liu is the Director and Principal Investigator of the MIT Learning Engineering and Practice (LEAP) Group, which investigates the intersection of learning technologies, STEM workforce and education, and digital learning and MOOCs. He is a Lecturer in MIT's Mechanical Engineering department and a Scientist in the MIT Digital Learning Lab. He leads education and workforce development efforts for MIT's new initiative: Manufacturing@MIT. He was the Director of the Principles of Manufacturing MicroMasters program, an online certificate program that has now enrolled over 200,000 learners across the globe. He has received several Best Paper Awards from ASEE and IEEE DEMOCon. He has co-authored dozens of publications and currently serves as an executive guest editor for Manufacturing Letters. His research is supported by the Department of Commerce, Department of Defense, Massachusetts Technology Collaborative, Schmidt Futures, National Science Foundation, MIT, and industry partners.

Note

The full paper will be available to logged in and registered conference attendees once the conference starts on June 22, 2025, and to all visitors after the conference ends on June 25, 2025

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