The Ultimate Guide to Augmented Reality (AR) in Manufacturing Industry

Augmented Reality in manufacturing is revolutionizing the industry and transforming how manufacturers do business. It has opened up new possibilities, empowering producers to innovate faster, increase efficiency, reduce costs, and create better products for a more intelligent, more connected world. AR has also made it easier for corporations to visualize and streamline complex concepts and processes, improve safety, and provide valuable insight into their operations. 

This comprehensive guide will look at how Augmented Reality is changing the manufacturing landscape and outline the steps manufacturers can take to get started with AR.

What Is AR Manufacturing?

Augmented Reality manufacturing is an advanced form of automation that incorporates digital technology into the production line. It combines the physical world with computer-generated graphics, data, and interactive elements to create an enhanced reality. AR manufacturing increases production efficiency by reducing the need for manual labor, increasing visibility into and control over the production process, and making it easier to customize products. 

AR solutions enable producers to identify potential problems, improve process flows, and optimize maintenance operations. This technology can reconstruct how factories operate by allowing production lines to become more agile, flexible, and cost-effective.

How Is AR Used in Manufacturing?

Augmented Reality for manufacturing is used in various ways, including but not limited to remote assembly, hands-free instructions, augmented quality control and expanded inventory management. Essentially, there are ten manufacturing-related areas where AR comes in handy these days:

Maintenance of the Equipment

AR can improve equipment maintenance by providing technicians with contextualized real-time information. Through an AR headset, technicians can access and apply detailed instructions while they work, eliminating trial and error and reducing downtime associated with machine maintenance operations.

For example, a company that produces car engines could leverage an AR-based platform to provide its technicians with the minutiae to disassemble an engine. The AR headset would display an animated 3D model of the engine, overlaid with interactive controls that provide detailed instructions for each procedure step. The technician can view the model from any angle, rotate it in real-time to get a better look at specific components, and zoom in for a closer view. Once the user completes one step, the model will automatically move on to the next, guiding the way. 

Asset Identification and Output of Current Equipment Indicators

Asset identification is one of the primary uses of AR in manufacturing. Personnel can quickly and accurately identify and track assets in real-time using AR. For instance, when servicing a piece of equipment, staff can use AR to accurately identify the equipment and leverage the digital data stored in their systems about that particular machine. This data can include information on the machine’s maintenance history, spare parts required, and more to help ensure technicians can quickly identify needed parts and repair or replace them.

AR can also provide the output of current equipment indicators. Producers use AR to access live data such as machine temperatures, humidity levels, and pressure settings. For example, a series of sensors connected to an AR headset may monitor a factory’s HVAC (Heating, Ventilation, and Air Conditioning) system. It could provide feedback on temperatures and humidity levels to maintain optimal working conditions within the production facility. 

Production Process Design

AR can be used in various stages of the product development process. The technology can provide numerous benefits, from prototyping and design refinement to production line automation.

In product design, for instance, AR can quickly create 3-dimensional models and build virtual prototypes. It enables designers to interact with the product in an immersive, realistic environment. 

Spatial Computing

AR has been instrumental in transforming spatial computing as a tool to visualize data in the physical world and to create an interactive experience with physical objects. AR helps streamline processes within a manufacturing environment by providing a way to view additional data and detailed context around the things being worked on.

For example, a producer may use Augmented Reality to learn about a particular material. It could include visualizing the material’s density, hardness, or other properties in 3D space using a headset such as an Oculus or HoloLens. The manufacturer could also use AR to preview how the part will look when completed and any potential flaws that need addressing during the production process.

Logistics

In the logistics sector, AR helps track and monitor products and materials throughout the entire supply chain. For example, AR can digitize inventory and supply chain management processes. It can accelerate delivery times and reduce manual tracking and data entry costs. Besides, AR can help workers recognize and identify parts or materials that need to be moved or handled in the warehouse or along a delivery route. For instance, using a headset display, employees can be guided through the warehouse to pick items, ensuring that the right products are selected and loaded quickly.

DHL has deep-dived into the AR industry by using the technology to help warehouse workers find items faster. With AR, employees can get detailed instructions, barcodes, and expiration dates superimposed into physical entities. 

Assembly

Augmented Reality is becoming an increasingly helpful tool for complex assembly processes, allowing for easier and more accurate operations. For example, an assembly operator may use AR glasses to access instructions and visual assistance in assembling a complex machine. These instructions can be displayed as 3D images or animations, which show the operator step-by-step how to complete the device correctly. 

A special device can also provide information about the location of each component, walk the operator through a sequence of tasks, and alert the person when a mission is complete. It not only increases the efficiency of the assembly process but also reduces potential errors and quality issues associated with manual assembly operations.

Communication Between Employees and Departments to Solve Problems

AR solutions can provide prompt assistance to workers by giving them quick access to instructions and even data or insights from other departments without leaving the factory floor. An automotive company can use an Augmented Reality application to guide workers in performing engine assembly tasks. It uses cameras, sensors, and a projection system to extend detailed instructions onto the workspace. It lets workers stay focused on their jobs while receiving help from other departments to solve any issues that may arise during the process. Besides speeding up the procedures, AR production helps reduce operating costs.

Quality Control

Using unique accessories empowers assurance personnel to quickly and accurately inspect products and components, visualize potential issues, and provide guidance on resolving them. This technology also enables remote collaboration between workers in different locations and increases the speed of quality checks. Leading companies have implemented Augmented Reality production systems that guide operators through the quality control process and automatically detect defects, reducing the time required to inspect products.

Staff Training

AR provides a venue for simulating real-world activities and situations in a semi-virtual environment. It, in turn, allows manufacturers to practice various activities without needing actual physical equipment or material. 

For example, AR can introduce new employees to the production line safely and interactively. By using 3D models and holograms of equipment, virtual representations of workflows, and realistic simulations of industrial processes, new workers can better understand their environment, the roles and responsibilities of each team member, and potential safety hazards.

Moreover, AR applications provide instant feedback on employee performance. When training on a specific activity or process, an AR system can provide visual or auditory cues if the steps are not completed correctly or if a worker takes too long. This feedback incentivizes users to maximize workforce productivity while minimizing errors.

Finally, AR in manufacturing provides safety training by using immersive environments to walk employees through potentially hazardous scenarios and providing real-time reactions such as visual warnings or audio prompts if they do not follow the correct safety protocol. 

Expert Support for Customers

Augmented Reality allows clients to connect remotely with a qualified technician who can view the customer’s environment in Augmented Reality and provide immediate assistance.

It could range from providing simple instructions to guiding users through complex procedures. Assume a customer encounters a problem with their machine. In that case, an expert can use AR to provide step-by-step troubleshooting instructions and even see the customer’s environment through a video feed.

Hololens from Microsoft provides multiple features for remote assistance. The software displays in 3D images assembly instructions and 3D schematics and enables technicians to draw annotations directly within a customer’s field of vision.

Advantages of AR in Manufacturing

• AR industrial applications can provide shop floor workers with infinite and contextual guidance at the point of need. It can sleek production processes and quickly alert workers to errors in real-time, enabling them to address issues before affecting productivity or quality. Additionally, such apps help visualize a finished product before producing it, providing workers with an understanding of how each component of their task fits into the bigger picture. 
• AR simplifies data access in manufacturing by providing access to a range of data points in a single view, improving decision-making. The technology does this by giving workers a visual representation of the data. It lets them see trends or possible efficiencies that are not immediately obvious from text or numbers alone. It also provides contextualized information, such as directions on how to use a machine or insights into machine performance. It simplifies data access and accelerates problem-solving and process optimization.
• AR reduces maintenance time in manufacturing by offering operators, technicians, and engineers live assistance with the maintenance process. Additionally, industrial Augmented Reality applications allow for remote help from experienced professionals to complete maintenance tasks rapidly. By providing these resources, AR reduces downtime and maintenance associated with complex repairs and ensures a higher quality product and faster delivery times. Finally, AR systems can detect mechanical anomalies and present the operator with potential solutions to prevent the issue from escalating.

Augmented Reality in Manufacturing Industry Share

The advancements in AR technology have been transforming the way manufacturing activities are conducted. In particular, the global Augmented Reality and Virtual Reality manufacturing market was valued at USD 5.6 billion in 2021 and is expected to grow at a compound annual growth rate (CAGR) of nearly 30% from this year to 2030. 

With key players such as Microsoft Corporation and Google LLC investing in AR technology, manufacturers are increasingly embracing this cutting-edge technology for improved cost-effectiveness and increased productivity.

PWC researchers have similar predictions, forecasting a potential boost of VR and AR in product and service development to GDP by $359.4 billion by 2030. It all highlights a promising future for Augmented Reality in manufacturing.

Best Companies Using AR in the Manufacturing Area

• Cisco Systems: Cisco Systems is a technology leader that uses manufacturing AR to enhance workplace safety. They have developed AR-enabled safety glasses, which provide workers with real-time information and safety notifications, allowing them to work more efficiently. 
• Siemens AG: Siemens AG is one of the leading providers of industrial Augmented Reality solutions and services. Using AR devices, Siemens has developed several products that improve building processes and workplace safety. For example, they have implemented AR-enabled goggles, allowing workers to access tracking and performance metrics and receive guidance on assembling and repairing components. 
• Dassault Systèmes: Dassault Systèmes is one of the leaders in the 3D design and product engineering field, and they extensively use Augmented Reality industrial applications in their manufacturing processes. Their 3DExperience platform allows employees to view essential information through AR headsets or tablets. It includes engineering drawings, parts lists, technical documents, ergonomics data, and interactive assembly instructions.
• Lockheed Martin: Lockheed Martin has integrated AR for manufacturing into its production processes to increase speed and accuracy. Their innovative AR system enables personnel to identify potential issues before they become major problems, resulting in improved workflow, better quality control, and faster production times.

Stages of Implementing AR in an Existing Manufacturing Business

1. Stage 1: Develop and Define Use Cases. The first step in implementing AR in an existing manufacturing business is to develop and define specific use cases for the technology. It involves assessing the business’s existing processes and technologies and determining which tasks can be enhanced or automated through AR.
2. Stage 2: Create a Prototype. Once you map out the use cases, the next step is to craft a prototype of the AR system to test it in a simulated environment. Testing the prototype will allow the team to define any potential shortcomings or problems that need addressing before implementing them.
3. Stage 3: Design and Develop the AR System. After testing and approving the prototype, it is time to design, develop, and implement the existing AR system. It includes identifying the hardware components necessary to run the system, designing and developing custom software solutions to enable the desired features, and integrating them into the enterprise.
4. Stage 4: Train Employees. Upon creating the AR, employees need to learn to use it effectively. It may involve formalized instruction or hands-on practice sessions with simulated components of the system.
5. Stage 5: Monitor and Maintain. The final stage of AR implementation is to monitor and maintain the system as needed. It includes regularly evaluating user feedback and adjusting settings to improve performance. Additionally, regular maintenance is essential to ensure the optimal operation of the system.

Augmented Reality in manufacturing is a powerful tool for companies looking to increase efficiency, reduce costs, and create a safer work environment. By leveraging this technology, brands can tap into the latest advancements in this field and gain a competitive edge in their business operations. 

With all the benefits provided above, equipping your manufacturing enterprise with AR industrial applications is just a matter of time. See how AR can revolutionize manufacturing in your business today. Transform how you operate and increase efficiency by unlocking the power of AR technology — drop us a line at hello@wear-studio.com whenever you’re ready to increase your company’s profits.