Enhancing PLC Education With Factory I/O: A Simulation‐Based Approach for Industrial Applications

ABSTRACT Rapid advances in industrial automation have made knowledge of Programmable Logic Controllers (PLCs) essential for engineering graduates. However, traditional PLC education often lacks practical and hands‐on learning opportunities, limiting students' ability to apply theoretical concepts in industrial contexts. This study proposes a simulation‐based instructional framework using the 3D industrial automation platform Factory I/O to enhance PLC education in alignment with the principles of Education 4.0 and Industry 4.0. Third‐year mechanical engineering students participated in open‐ended experimentation activities in which they designed and simulated virtual factory automation systems using PLC programming and logic development. The instructional approach integrated competency‐based learning, simulation‐driven experimentation, and outcome‐based assessment aligned with Program Outcomes (POs). The results indicate that the use of Factory I/O improved students' conceptual understanding, logical reasoning, technical proficiency, and system‐level thinking. Students also demonstrated higher engagement and enhanced problem‐solving abilities while working on industrial automation scenarios. Outcome‐based assessment showed strong attainment of PO5 related to modern engineering tool usage and PSO3 (PO15) associated with technology integration. In addition, several student teams documented their work as technical papers and presented them at an international conference, supporting the development of research communication skills. The findings demonstrate that simulation‐based PLC education using Factory I/O provides an effective and scalable approach for bridging theoretical learning with industrial automation practice and for improving graduate readiness for Industry 4.0 applications.