Smart Manufacturing Operations Become Even Smarter With AR and VR

The time is right for smart manufacturing organizations to adopt -- or expand -- their use, of AR and VR.  While the world of augmented reality (AR) and virtual reality (VR) may be best known for such games as Pokémon GO and The Machines for the former and Minecraft VR and Need for Speed VR for the latter, both technologies are becoming an important part of the underlying strategy of firms adopting smart manufacturing methodologies.

An increasing number of firms are using AR or VR – or both – as part of their smart manufacturing initiatives.  Both are proving to be powerful tools to be leveraged by leading manufacturing firms. With their deep insight into maintenance and operations information, asset geolocation data, as-built specs, and potential hazards, both AR and VR can significantly improve the efficiency, effectiveness, and safety of manufacturing organizations.   

Practical Uses of AR and VR in Smart Manufacturing

So, what are the differences between these two technologies? In general, AR includes overlays of such information as asset attribute and location data, operating parameters, maintenance instructions, or workflow instructions, particularly as they relate to physical assets.  VR is set entirely in an artificial – a digital – world.  AR is often expressed via apps on smartphones and tablets.  VR is often used to display “digital twin” information, which includes virtual representations of assets, buildings, and systems from 3D CAD, visualization, simulation, and similar systems.

Interest and usage of AR and VR are on the rise, with more than half of manufacturing organizations testing these technologies.  Some of the main reasons cited in a recent Bank of America Merrill Lynch report include the potential to improve productivity by up to 40%; a reduction of installation and maintenance costs by between 25% and 60%; and output improvements of between 40% and 90%, primarily  because of increased accuracy

There are a wide variety of ways that AR and VR can help smart manufacturing organizations reach their full potential.  Particularly noteworthy is the potential for improved labor productivity and task performance.  This can allow workers to more quickly find and understand important equipment and workflow information, resulting in tasks being completed more quickly and thoroughly. 

AR Use in EAM and QC

An example of such performance improvements can be found in a study noted in a Harvard Business Review. This study, which looked at how AR is improving worker performance, reports about a GE technician who wired a wind turbine’s control box in the traditional manner — reviewing the instruction manual, turning to the turbine, turning back to the instructions, etc. — and performing the same task while guided by line-of-sight instructions overlaid via an AR headset. The AR-based device improved the worker’s performance by over a third during its first use. 

AR and VR can be valuable tools beyond labor productivity and process improvements. Some firms are using these tools to improve product innovation and testing by enabling engineers to make adjustments and modifications, when appropriate.  

Airbus uses its Supply Augmented Reality Tool (SART) solution to increase efficiency and improve quality control at its installation and inspection facilities. Employees use a tablet to overlay a digital mockup over images of real systems to identify faulty parts that need to be repaired or replaced.

The age of AR and VR is clearly upon us. Their practical use is more than a future vision and is fast becoming a reality at many progressive smart manufacturing firms. As more and more firms become aware of the potential for AR and VR to make their operations more efficient and productive, they will look to invest in these technologies to augment similar advances occurring in data management, AI, and machine learning.