Virtual technology has existed for greater than 50 years. However, augmented reality (AR) and virtual reality (VR) have only recently emerged in manufacturing environments. Early adopters have begun using virtual technology in myriad ways — mainly, to enhance employee safety, speed latest products to market, reduce training costs and increase productivity.
Augmented reality use cases are growing more common in businesses today. For example, corporations like Harley-Davidson, Ford, Walmart and Chipotle use this technology to fabricate products and train latest employees.
How VR and AR technologies are changing manufacturing
VR and AR technologies have multiple applications within the manufacturing industry, a lot of which have already been implemented by forward-thinking corporations.
Inventory management
Logistics company DHL was among the many first to include AR in its inventory management. In collaboration with Ricoh, a DHL customer, and wearable computing solutions expert Ubimax, DHL launched a “vision picking” pilot program. It did so in its warehousing operations using AR smart glasses.
Graphics displayed on the smart glasses guided employees through the warehouse to scale back errors and quicken the picking process. The smart glasses recorded mandatory tracking data without the worker needing to stop and enter data right into a computer. The pilot program proved that AR offers added value to logistics; it resulted in a 15 percent efficiency increase through the picking process. DHL has since implemented this technology in warehouses around the globe.
Product design and assembly
VR has proven particularly helpful in streamlining product design and reducing its associated costs.
“Virtual reality … [allows] teams to visualise, test, and refine concepts quickly and cost-effectively,” explained John Brooks, CEO and founding father of Mass Virtual, a software company that develops prolonged reality (XR) training solutions. “It enables corporations to dream big, turning ambitious ideas into tangible, digestible forms, helping them see the feasibility of grand systems in minutes.”
In addition to improved prototyping, VR can even facilitate the physical assembly process. For example, smart goggles with depth sensors, cameras and motion sensors offer a comprehensive view of the working environment. They show engineers and employees learn how to assemble parts and follow instructions accurately. Boeing technicians use VR smart glasses to access mandatory instructions for every wiring repair — cutting work time by 25 percent.
Maintenance and assembly training
AR and VR can improve the onboarding process and boost productivity by offering more immersive on-the-job training. For example, AR smart glasses that project video, graphics and text can visually guide a employee, step-by-step, through assembly or maintenance tasks. VR can even simulate assembly line configurations and production processes. This allows teams to higher discover and address potentially dangerous situations.
“Immersive VR simulations help us to show the employees the intricacies of assembly process, machine operation and safety procedures,” said Tom Kohm, CEO of Premier Equipment, Inc. “We have found this to be way more effective in training than the normal method; training time has been reduced, and knowledge retention has improved.”
Factory floor planning
Virtual technology can be being implemented for factory floor planning, construction and manufacturing trade events. In mass-production manufacturing, factory planning — where to position tools, equipment and personnel — is crucial for productivity and efficiency.
Engineering a brand new plant or altering an existing one involves detailed design, testing and trials. Any unexpected delays or a production line shutdown, even a short lived one, may be very costly. Virtual technologies can simplify and significantly shorten the method. Virtual plants may be designed to check production flows and the way employees and robots perform tasks before making any actual changes.
The way forward for VR in manufacturing
While VR’s impact on the manufacturing industry is noticeable, not all corporations have made the leap. This is due, at the least partially, to the hardware required. As Sirotin noted, current VR hardware has significant limitations as a consequence of battery life, comfort and other physical challenges.
However, Brooks believes this might change within the not-too-distant future. “VR will grow to be as essential in manufacturing as smartphones, because of rapid advancements in hardware and AI-powered systems,” Brooks predicted. “These breakthroughs will result in widespread adoption — unlocking more immersive, efficient and revolutionary applications throughout the industry.”
One such potential advancement is VR’s integration with AI and the Internet of Things. According to Kohm, these integrated systems can visualize real-time data and perform predictive maintenance in virtual environments.
Kohm also predicts that digital twins — virtual representations of physical objects or systems — will grow to be more widely adopted as VR technology advances. “Physical manufacturing facilities will grow to be virtual and standard, providing complete simulation and optimization of entire production lines prior to implementation,” Kohm explained.
In addition to increased implementation inside the factory, Sirotin anticipates VR will take a much bigger role in the sphere.
“The ability to deliver visual cues to field service teams through AR/VR tools allows for more efficient deployment of resources — less training for service techs and a greater ability to resolve problems in the sphere,” Sirotin said. “Equipment corresponding to machine tools, coordinate measurement machines, robotics and automation components all require continuous maintenance. XR can speed up that process and deliver more uptime for manufacturers.”
