Combining Virtual Reality with the Physical Model Factory: A Practice Course Designed for Manufacturing Process Education

Diverse model factories have been established in universities and enterprises to support practical education across various fields. Increasingly stringent health and safety regulations have made practical equipment more complex and costlier. With the advancement of digital infrastructure, virtual reality (VR) technology has been widely adopted in education to simulate real-world environments. This study explores the application of VR technology in enhancing manufacturing process education. To achieve this, an interaction methodology based on the OPC UA standard is proposed to enable data exchange between virtual and physical environments. Additionally, a detailed workflow of the practice course, conducted in a physical model factory at North China University of Technology, is presented. This approach is particularly noteworthy because it allows students to validate simulated results using a physical system, rather than relying solely on virtual scenes to mimic real-world settings. Students were divided into two groups: a practice group using the proposed digital method, and a control group without digital tools. The number of mistakes from the practice group was 37% less than that of the control group. Statistical analysis of students’ grades and questionnaire responses concludes that the proposed methodology is valuable to improve students’ engagement and practical skills. The presented course is replicable for other training institutions.