A framework for digitisation of manual manufacturing task knowledge using gaming interface technology

Intense market competition and the global skill supply crunch are hurting the manufacturing industry, which is heavily dependent on skilled labour. Companies must look for innovative ways to acquire manufacturing skills from their experts and transfer them to novices and eventually to machines to remain competitive. There is a lack of systematic processes in the manufacturing industry and research for cost-effective capture and transfer of human skills. Therefore, the aim of this research is to develop a framework for digitisation of manual manufacturing task knowledge, a major constituent of which is human skill. The proposed digitisation framework is based on the theory of human-workpiece interactions that is developed in this research. The unique aspect of the framework is the use of consumer-grade gaming interface technology to capture and record manual manufacturing tasks in digital form to enable the extraction, decoding and transfer of manufacturing knowledge constituents that are associated with the task. The framework is implemented, tested and refined using 5 case studies, including 1 toy assembly task, 2 real-life-like assembly tasks, 1 simulated assembly task and 1 real-life composite layup task. It is successfully validated based on the outcomes of the case studies and a benchmarking exercise that was conducted to evaluate its performance. This research contributes to knowledge in five main areas, namely, (1) the theory of human-workpiece interactions to decipher human behaviour in manual manufacturing tasks, (2) a cohesive and holistic framework to digitise manual manufacturing task knowledge, especially tacit knowledge such as human action and reaction skills, (3) the use of low-cost gaming interface technology to capture human actions and the effect of those actions on workpieces during a manufacturing task, (4) a new way to use hidden Markov modelling to produce digital skill models to represent human ability to perform complex tasks and (5) extraction and decoding of manufacturing knowledge constituents from the digital skill models

Human factors of future rail intelligent infrastructure

The introduction of highly reliable sensors and remote condition monitoring equipment will change the form and functionality of maintenance and engineering systems within many infrastructure sectors. Process, transport and infrastructure companies are increasingly looking to intelligent infrastructure to increase reliability and decrease costs in the future, but such systems will present many new (and some old) human factor challenges. As the first substantial piece of human factors work examining future railway intelligent infrastructure, this thesis has an overall goal to establish a human factors knowledge base regarding intelligent infrastructure systems, as used in tomorrow’s railway but also in many other sectors and industries. An in-depth interview study with senior railway specialists involved with intelligent infrastructure allowed the development and verification of a framework which explains the functions, activities and data processing stages involved. The framework includes a consideration of future roles and activities involved with intelligent infrastructure, their sequence and the most relevant human factor issues associated with them, especially the provision of the right information in the right quantity and form to the right people. In a substantial fieldwork study, a combination of qualitative and quantitative methods was employed to facilitate an understanding of alarm handling and fault finding in railway electrical control and maintenance control domains. These functions had been previously determined to be of immediate relevance to work systems in the future intelligent infrastructure. Participants in these studies were real railway operators as it was important to capture users’ cognition in their work settings. Methods used included direct observation, debriefs and retrospective protocols and knowledge elicitation. Analyses of alarm handling and fault finding within real-life work settings facilitated a comprehensive understanding of the use of artefacts, alarm and fault initiated activities, along with sources of difficulty and coping strategies in these complex work settings. The main source of difficulty was found to be information deficiency (excessive or insufficient information). Each role requires different levels and amounts of information, a key to good design of future intelligent infrastructure. The findings from the field studies led to hypotheses about the impact of presenting various levels of information on the performance of operators for different stages of alarm handling. A laboratory study subsequently confirmed these hypotheses. The research findings have led to the development of guidance for developers and the rail industry to create a more effective railway intelligent infrastructure system and have also enhanced human factors understanding of alarm handling activities in electrical control

Human factors of future rail intelligent infrastructure

The introduction of highly reliable sensors and remote condition monitoring equipment will change the form and functionality of maintenance and engineering systems within many infrastructure sectors. Process, transport and infrastructure companies are increasingly looking to intelligent infrastructure to increase reliability and decrease costs in the future, but such systems will present many new (and some old) human factor challenges. As the first substantial piece of human factors work examining future railway intelligent infrastructure, this thesis has an overall goal to establish a human factors knowledge base regarding intelligent infrastructure systems, as used in tomorrow’s railway but also in many other sectors and industries. An in-depth interview study with senior railway specialists involved with intelligent infrastructure allowed the development and verification of a framework which explains the functions, activities and data processing stages involved. The framework includes a consideration of future roles and activities involved with intelligent infrastructure, their sequence and the most relevant human factor issues associated with them, especially the provision of the right information in the right quantity and form to the right people. In a substantial fieldwork study, a combination of qualitative and quantitative methods was employed to facilitate an understanding of alarm handling and fault finding in railway electrical control and maintenance control domains. These functions had been previously determined to be of immediate relevance to work systems in the future intelligent infrastructure. Participants in these studies were real railway operators as it was important to capture users’ cognition in their work settings. Methods used included direct observation, debriefs and retrospective protocols and knowledge elicitation. Analyses of alarm handling and fault finding within real-life work settings facilitated a comprehensive understanding of the use of artefacts, alarm and fault initiated activities, along with sources of difficulty and coping strategies in these complex work settings. The main source of difficulty was found to be information deficiency (excessive or insufficient information). Each role requires different levels and amounts of information, a key to good design of future intelligent infrastructure. The findings from the field studies led to hypotheses about the impact of presenting various levels of information on the performance of operators for different stages of alarm handling. A laboratory study subsequently confirmed these hypotheses. The research findings have led to the development of guidance for developers and the rail industry to create a more effective railway intelligent infrastructure system and have also enhanced human factors understanding of alarm handling activities in electrical control