Beyond the Machine: The Human Edge You Need to Win in the Industrial Metaverse

In the age of Industry 4.0, where the boundaries of physical factory floor and the digital thread are continually blurred, automotive manufacturers are seeking the next frontier for competitive advantage. This frontier lies in the realm of human-centered design and leveraging the human element to optimize the future Industrial Metaverse production processes. As CInOs navigate this evolving landscape, integrating human factors into virtual production environments is not just a possibility; it is a strategic imperative.

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The Human Element in the Digital Framework

With advancements in virtual production environments from companies like Siemens' Tecnomatix, GE Digital’s Predix, PTC’s Vuforia, or Dassault Systèmes 3DEXPERIENCE, to name a few, platform manufacturers can now create highly accurate replicas of their production lines. These digital twins allow for real-time simulations and adjustments, optimizing the efficiency and output of manufacturing processes. However, there is a vital component that is still often overlooked: the human element.

Imagine a VR (Virtual Reality) simulation not just focusing on how a worker reaches for a specific tool but also on the subtle cues of fatigue. The worker's virtual avatar starts moving slower, their grip loosens on the tool, or their virtual brow furrows in frustration. These subtle changes, captured through advanced motion capture technology, could indicate potential ergonomic issues or early signs of fatigue before they lead to a real-world accident or productivity dip. Emteq labs are currently testing facial optomyography glasses for behavioral analytics and emotional sensing.

Human workers are not mere cogs in the industrial machine; they are the lifeblood of any manufacturing operation. Their insights, emotions, and physical well-being play a critical role in the nuanced ecosystem of a factory floor. So, how can we integrate this human element more deeply into the digital twins? Hollywood's storytelling tools could offer a compelling answer.

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Storytelling as a Tool for Empathy

Hollywood has mastered the art of empathy. Through storytelling, filmmakers create emotional connections with audiences, allowing them to understand and feel the characters' joys, sorrows, and challenges. In a similar vein, we can use these tools to script scenarios in our digital twins that do more than simulate mechanical actions; they can also simulate and analyze human interactions and ergonomics.

Ford's adoption of VR training simulations for technicians working on the electric Mustang Mach-E is an early example of leveraging storytelling to bridge the gap between the digital and human elements.

Using software like Tecnomatix from Siemens, through VR simulations, we can now explore not just how human movements affect manufacturing processes but also how these processes affect humans. Dr. Frank Emrich , CEO of Scalefit developed the Digital Athlete program, and equipped with Movella's motion capture suite, they are analyzing workplace ergonomics, demonstrating how technology can address the physical stress points of workers. But what about their emotional and mental health?

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Emotional Intelligence in Digital Twins

Smart manufacturing through digitalization, simulation, and virtual representation is driving sustainable production. Factories can now capture a staggering amount of data – 2,200 terabytes in a single month, according to Cedrik Neike , CEO of Siemens Digital Industries, in his Keynote at CES 2024. However, this data deluge presents a challenge: sifting through it to find the most impactful insights. While we excel at monitoring machine performance, are we capturing all the right data? Are we equally focused on the human element, monitoring the mental strain and emotional well-being of our workforce?

Integrating emotional intelligence into digital twins could be the next step. Imagine a digital twin that not only predicts the failure of a machine but also anticipates human errors based on stress levels or fatigue. By doing so, we could preemptively offer breaks, adjust workflows, or provide support, enhancing both productivity and worker sustainability.

By anticipating human errors and preemptively offering breaks or adjusting workflows, the potential impact on accident reduction is significant. Considering the role fatigue and stress play in human error, a conservative estimate suggests a possible 15% reduction in workplace accidents.

Accounting for Diversity in Simulations

Another critical aspect is diversity. Each worker brings a unique perspective that can potentially offer new insights into improving processes. Our digital twins should reflect this diversity, not just in terms of ergonomic data but also in modeling different cognitive styles and emotional responses. This approach would not just make our digital twins more comprehensive but also unlock a wider range of problem-solving approaches, leading to a more innovative and adaptable manufacturing environment.

General Motors' early investment in collaborative robots designed to work alongside human workers exemplifies the commitment to a diverse and human-centric approach. Today, we have workers safely alongside Cobots guided by ISO 10218 standardization. By simulating human-robot interaction within digital twins, companies can ensure a smooth and safe integration process on the factory floor.

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Conclusion: The Path Forward with Empathy

As we stand on the brink of the Industrial Metaverse, the next phase of industrial evolution is not just about more sophisticated machines or smarter AI. It fosters an environment where technology understands and enhances the human experience at every level.

We can create a more holistic, effective, and humane industrial future, by borrowing narrative techniques from the films we love and diverse industries. Developing empathy in our digital tools is imperative, not just an opportunity. Pushing the boundaries of technology with human-centered design creates more positive work experience and positions companies as leaders in a future defined by empathetic and sustainable manufacturing.

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Are you ready to explore how empathy can transform your digital twins? Share your thoughts in the comments below!

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