Have you ever tried to follow a recipe only to be confused when some of the steps are missing? Sometimes, when we share instructions with someone else, we forget to describe steps that seem obvious. “Mix the batter” or “Turn on the oven” might be obvious to you, but without those crucial pieces of information, the budding chef may make significant mistakes.

The same is true in manufacturing. It’s important that you track not only what you should be doing, but also what you have done, and to keep track of any other important data along the way.

In advanced manufacturing, it's not only important to have great instructions it's also important to know if every step of the process is proceeding as planned. It’s important that you track not only what should be happening, but also what has been done or not done, and to keep track of any other important data along the way (e.g. Is it time to order more parts or do maintenance? )

Imagine a fast food restaurant. Food items are prepared and assembled in a uniform and standardized way, regardless of the location. A cheeseburger will taste the same in Phoenix as it does in Toledo. But this doesn't happen by accident. Clear preparation and assembly instructions are created and shared among the franchises so that the products are all the same. This is similar to what is collected and shared through what is called "the digital thread" in advanced manufacturing. The digital thread is, in many ways, like the electronic nervous system of the advanced manufacturing process. Specific and detailed instructions for manufacturing a product are digitally accessible throughout the manufacturing process via the digital thread so that the products are all standardized and uniform and any problems and can be addressed quickly to avoid costly downtown, waste, and safety concerns. 

In this activity, you will be inspired by work done at the Newport News Shipbuilding to manufacture a model boat out of interlocking building blocks while collecting data to be shared in a simulated digital thread, sharing all of the important information about your manufacturing process with others in the product's production process.

Figure 1: Lego building blocks

Materials:

• Device with internet access
• Access to Google Drive applications including Google Docs and Google Sheets
• Interlocking building blocks set
• Digital Thread Data Collecting activity sheet found in the shared Google Drive.

Safety Notes:

• When using technology, engage in safe, legal, and ethical behavior; this applies to devices (hardware), application or programs (software), and interactions with others.
• There are no anticipated physical safety risks associated with this Activity.

Part 1: Feeding Data into the Digital Thread

Table 1: Digital Thread Data Collecting activity sheet

1. Work with your group to design a boat using interlocking building blocks using Tinkercad or building block software. Web Link - Play with virtual LEGOs using open source tools
2. Once your group has agreed upon a design, draft clear assembly instructions using both images and text.
3. Upload your assembly instructions to the shared Google Drive.
4. With your group, decide what you need to track when building your structure so that someone can either replicate it or complete it. 

Part 2: Manufacturing the Boats

3. Your group will now assemble another group's boat. Follow your teacher's instructions about which boat to manufacture. Tell groups to find the assembly instructions for the group with the next letter in the alphabet (group A assembles group B's boat, etc.). For this first round, they will be completing the "Assembly Step" and "Round 1" Columns on the top part of the sheet. They should use as many rows as is necessary as they are working and can add additional rows to the table.
4. Follow the instructions posted in the shared Google Drive to manufacture the boat.
5. As you are building the boat, collect data about your production process and record it on the Digital Thread Data Collecting activity sheet. You will be recording each building step as you work. Include any relevant information to improve the assembly instructions in the "sensor" column such as more detailed instructions, or how many of each shape you will need for that step. In advanced manufacturing, sensors are used to give data and production feedback to the manufacturer in the digital thread in order to increase efficiency and safety. After 6 minutes, pause the activity without warning.

Part 3: The Hand-Off

Figure 2: Cars built out of Lego building blocks

4. Tell students that they have completed their shifts in the manufacturing facility and the next group will continue working on assembling their boat. When students have shifted to the next boat, give them the Round 2 Production Issue. Tell them to remove all of their blue pieces from their remaining pieces. Have them add "Supply issue: remove blue pieces". Then have them discuss with their groups the consequence of the production issue and note it on their Digital Thread Data Collecting sheet. They can then brainstorm with their group's solutions for their production issue and note it on the sheet, as well. Once you have resolved your production issue, begin assembling the boat using both the original assembly instructions and the Digital Thread Data Collecting sheet. Be sure to note any "sensor" feedback from the prior group. Begin assembling your vehicle.
5. Be sure to keep your Digital Thread Data Collecting sheet current. Allow students 6 minutes to build their next boats. At the end of 6 minutes, pause the activity once again. Tell students that they have completed their shifts in the manufacturing facility and the next group will continue working on assembling their boat. When students have shifted to the next boat, give them the Round 3 Production Issue. Tell them to remove half of their remaining pieces. Have them add "Supply issue: limited pieces". Then have them discuss with their groups the consequence of the production issue and note it on their Digital Thread Data Collecting sheet. They can then brainstorm with their group's solutions for their production issue and note it on the sheet, as well. Once you have resolved your production issue, begin assembling the boat using both the original assembly instructions and the Digital Thread Data Collecting sheet. Be sure to note any "sensor" feedback from the prior groups. Begin assembling your vehicle. Stop the activity after 6 minutes.

Reflect and Apply:

• Have students return to their original designs and examine both the assembled boat and the Digital Thread Data Collection sheet. Then, hold a class discussion to answer these questions:
  • What information did other groups record that your group did not? 
  • What do you think "good directions" need to include?
  • What information were you most in need of but did not have?
  • Which was most helpful: directions in text or directions in images? Why?
  • How did your prior experience in previous groups help you with the latter groups? 
  • How did sensors help you to be more efficient in your assembly process?
• Watch this video: Web Link - Understanding the Digital Thread . How does the activity you just participated in simulate the digital thread? 

Extension:

• Work with your fidget widget group from Module 1 to create a Digital Thread Data Collection sheet for your Fidget Widget design.
• Journal Question: Do you consider assembling interlocking building block structures to be manufacturing? Why or why not?

Additional Resources to Explore:

• Web Link - Digital Thread in Manufacturing Digital Thread Discussion
• Web Link - What is a Digital Twin? Learn more about digital twins 
• Web Link - Play with virtual LEGOs using open source tools You can build other creations using virtual bricks and CAD software.