Digital Twin-Based Active Learning for Industrial Process Control and Supervision in Industry 4.0

The integration of Digital Twin technology into active learning environments has been established as an innovative strategy to optimize engineering education. This study focuses on the development and evaluation of a learning tool based on Digital Twin technology, enabling interaction and communication between a physical teaching module and a virtualized environment representing the industrial cocoa production process. The system was operated by students using an S7-1200 PLC and an HMI interface developed in WinCC, facilitating real-time process monitoring and control via IoT. To assess its impact, an experimental design was implemented, comparing a pre-test using conventional teaching modules with a post-test incorporating Digital Twin technology. The results indicate a significant improvement in students' accuracy and efficiency, with a 38% reduction in task execution time. This improvement is attributed to the system's immersive and interactive capabilities, which allow for the simulation of actuator and sensor behavior under real-world conditions. These findings highlight the potential of Digital Twins not only as educational tools but also as valuable assets for industrial process optimization in the cocoa sector, aligning with Industry 4.0 principles.