Have You Heard? Augmented Reality In Manufacturing Is a Part of Industry 4.0 Revolution. Learn These 5 Successful Ways | Augrealitypedia

Augmented Reality in Manufacturing (Image Credit: Office of Naval Research)

Many people still think the Augmented reality as the technology used in the games like Pokemon go. But, this technology has already extended its wings into several other sectors, like Education, Marketing, Medical, Manufacturing, Retail, etc.

I have covered various applications of AR in my earlier blog posts. But, today I will discuss about the applications of Augmented reality in manufacturing.

You will come to know that many manufacturing companies are already implementing Augmented reality, not only on the shop-floor rather also as an important tool to bridge the skill gap of their employees. Moreover, real-time integration of the real world with digital world makes Augmented reality perfect for the fourth industrial revolution.

Thus, before proceeding to the various applications of Augmented reality in manufacturing, let’s understand:-

1. What is “Industry 4.0” or “Fourth Industrial Revolution“?
2. What’s the role of Augmented Reality in the fourth industrial revolution?

Well, Fourth Industrial Revolution (4IR) is the current development stage of industries equipped with a number of sensors and modern technologies. The purpose of this resolution is to create smart factories with digitally connected machines.

Also, these machines generate and analyze the bunch of data in such a way that they can predict the probable failure well before it occurs and inform the preventive action to be taken to avoid the same.

And, the latest technologies like, Augmented reality (AR), Artificial Intelligence (AI), Industrial Internet of Things (IIoT), Cloud computing and Block-chain Technology support this automation and digitization of these data-centric industries.

While others yet to be introduced in the industrial sector, many companies have already started using Augmented reality in manufacturing activities.

5 Ways Augmented Reality Revolutionize The Manufacturing :

With the recent advancement in hardware configuration and data handling capability, Augmented reality enters into the mainstream. And, various manufacturing companies are already utilizing this amazing technology to improve their productivity and efficiency.

Moreover, in the manufacturing industries, AR can be integrated into the various functions, e.g, design, production, quality control, maintenance and personnel training. So, let me explain the 5 ways Augmented Reality is already revolutionizing the Manufacturing.

#1. Design with Augmented Reality : ThyssenKrupp

Well, my first selection demonstrates the application of Augmented reality in the initial stages of any New Product Development project. These stages include five major steps :-

1. To understand the customer requirement.
2. Convert customer requirement into related technical inputs.
3. Provide various solutions.
4. Select the most feasible solution acceptable to the customer.
5. Transfer the exact requirement to manufacturing team.

Being in a manufacturing sector, you can understand the importance and complexity of the above steps. Also, it takes a lot of effort and time to finalize the best feasible and economical product to both customer and the company.

But, the above cumbersome process can be made simpler and accurate by integrating the Augmented Reality into the early stages of development phase itself.

One of the world known stair-lift installation company, ThyssenKrupp has done exactly the same. They have equipped their salespersons with the Microsoft HoloLens.

Thus, whenever the salesperson visits the actual site, he can measure the staircase using the Microsoft HoloLens. And, using Augmented reality technology, he captures the 3D Point cloud data related to the actual environment.

Now, he shares this data with the concerned department of the company. And, based on the near real-time feedback, he can provide the various solutions to customers.

Additionally, Microsoft HoloLens also allows the sales person to superimpose the virtual 3D model of a stair-lift on the existing real stairs. Thus, customers can easily visualize “how it would look and function afterwards once installed in their home?”

The below YouTube video demonstrates the integration of Augmented reality in the initial development stage of stair-lifts manufacturing.

Moreover, the interactive nature of Augmented reality allows the customer to make his decision fast and firm. And, at the same time, it helps companies to manufacture their product fast, cost-effective and accurate to their customer’s need.

#2. Augmented Reality in Assembly Process: Boeing

My next selection demonstrates the utilization of Augmented reality during the Assembly Process in manufacturing.

As you know that in the case of manual assembly process, cycle time to complete the assembly depends upon the skills of the operator involved. Also, the performance of the operator matters a lot for the completion of the process perfectly in a single attempt.

For each step of the assembly process, the operator is bound to follow the work instruction, displayed near by his working area. Imagine the mental situation of the operator after an assembly process consisting of hundreds of steps.

He must be in a constant mental pressure always. And, this leads to degrade the performance and generate an error in his work. Ultimately, the company suffers with a huge loss.

The world’s leading commercial jetliner manufacturer Boeing face the same situation during the wire harness assembly consisting of thousands of wires. But, they come up with a unique solution to ease this assembly process by integrating Augmented Reality in their manufacturing (Assembly) process.

How does Augmented Reality help Boeing to improve the productivity?

Well, instead of work instruction sheets and diagrams, the company has equipped their technicians with the Google Glass. And, during each step of the assembly process, Augmented reality projects the instruction related to that particular step only.

Thus, Augmented reality and the various interactive interface of Google glass enable the technician to focus only on the assembly. And, it eliminates the need of referring the instructions constantly.

AR works as a virtual assistant and thus ease the pressure on the technician. Ultimately, it improves the overall productivity by reducing the no. of errors and cycle time to complete the assembly process. The below YouTube video demonstrates the Augmented reality based wire harness assembly at Boeing.

Moreover, according to Boeing, the integration of Augmented reality in manufacturing helps them to cut the production time by 25%. Also, it reduces the error rate to nearly zero.

#3. Augmented Reality Assisted Quality Inspection : Magna

Let me introduce you about the integration of Augmented reality with an another important step of the manufacturing process, i.e., Quality Inspection.

How does Augmented reality assist in quality control?

Well, process of quality inspection ensures that the product you supply to your customers meet all required specifications. Traditionally, this is done with the help of a checklist consisting a large number of checkpoints.

And, quality inspector needs to fill out this checklist before allowing (or, rejecting) the product for final delivery. Thus, the quality of the final product, that your customer receives depends not only on the quality of producing a product but also on the accuracy of the inspection process.

One of the AR assisted quality control process allows you to overlay the 3D CAD data on the live video of the actual product. Additional information like, dimensional accuracy, tolerances, interference and surface finish can also be displayed in the real-time.

Moreover, AR headset, like Microsoft HoloLens allows you to project this augmented version of information directly on the product to be inspected. In other words, Augmented reality integrated into the quality control methods provides an interactive platform to perform the complex task easily and in a more efficient way.

One of the well known global Automotive supplier, Magna, with the help of the Holo-Light has developed a software solution for the quality control process. The program is useful for  inspecting a car for potential defects with the help of Microsoft HoloLens.

Whenever, a quality inspector wearing his HoloLens looks toward the car, the software highlights only the parts to be inspected. Additionally, the inspector is also guided through a step-by-step procedure for inspection. The below YouTube video demonstrates the Augmented reality assisted quality control at Magna.

#4. Maintenance and Service using Augmented Reality : Caterpillar

Here, I will demonstrate the effectiveness of Augmented reality in Maintenance, another important pillar of any manufacturing industry.

How does Augmented reality help in maintenance and repair work?

Well, irrespective of the industry you belong, you must know the importance of regular maintenance of any equipment. However, maintenance of equipment related to the manufacturing industry is more complex than your household goods.

And, it requires a thorough knowledge of each and every corner of the equipment in terms of construction and function both. Additionally, the technician must refer a service manual with several hundreds of pages consisting technical diagrams and relevant information.

Now, imagine a situation. You look towards a particular component of a heavy machinery and the information only relevant to that component pops out in front of you and that too in the real-time. Yes, Augmented reality can do exactly this for you.

One of the world’s famous heavy equipment manufacturers, Caterpillar is effectively utilizing Augmented reality for the maintenance and repair work. They have developed their own service AR App.

You can run this application on your smartphone, tablet or even on your AR headset. Whenever, you point your device towards an equipment, the application guide you through the interactive visual step-by-step procedure to perform the maintenance or repair work. The below YouTube video demonstrates the Augmented Reality based maintenance at Caterpillar.

Additionally, you can also snap step wise pictures of the whole process. Nevertheless, voice-controlled futuristic AR glasses allow you to be hands free while performing the task.

#5. Training with Augmented Reality : Bosch

Till now, I have discussed the role of Augmented reality in Design, Assembly, Quality control and Maintenance. Here, I will demonstrate the application of Augmented reality in the Personnel training.

How does Augmented reality  help manufacturing companies to train their workforce?

You must know that a good training not only hone the skills of the workforce rather it create a more productive, safer and more efficient working environment. And, companies invest a huge amount of time and money for various high quality training activities.

Thus, effectiveness of the training matters a lot for the company and the employee both. But, traditional way of paper or monitor-based training is not so helpful to retain the training benefits in the trainee’s mind for a longer duration.

Once integrated with Augmented reality, boring training manual becomes interactive in nature. And, the superimposition of realistic 3D models on it imprints a long lasting effect in employee’s mind.

Key benefits of Augmented reality based training can be listed out as below:-

• Improve employee engagement.
• Can easily train remotely located employees.
• Eliminates the need for consulting manuals frequently.
• Break the language barrier to understand the training material.
• Ensure complete safety during the training.

A well known automotive company, Bosch has developed an AR program, named Common Augmented Reality Platform (CAP). This program enables you to superimpose (AR overlay) various digital contents into the physical training programs, manual etc.

The digital contents can be anything like text instructions, image, animation, video clip, audio clip, circuit diagrams,  3d model etc. The below YouTube video demonstrates the Augmented reality based training for automotive workshop.

Moreover, the interactive interface of this AR platform allows you to visualize the area of interest in more detail (zoom, rotate, etc.) using the simple hand gestures.

Wrapping up

To summarize, Augmented reality has a great potential to revolutionize the manufacturing industry. And, many companies introduce Augmented reality in manufacturing to ease their major pain area (e.g. Product design, Production, Quality control, Maintenance, Training, etc.).

Moreover, they have set a benchmark for others by proving it helpful to achieve a better productivity and efficiency along with the near zero error and low skill gap. Now, other companies can also identify their needs and integrate Augmented reality in manufacturing with more innovative ways to improve the efficiency of operations and workforce. 

That’s all from my side. In the comment section, let me know what you have liked the most? And, If you like my post, do share it with your friends. Also, do let me know about your queries related to augmented reality, if any.

I will try my best to resolve them through my successive blog posts. To keep yourself updated about Augmented reality, don’t forget to subscribe to my website. Additionally, visit my Facebook page and do follow @Augrealitypedia on Twitter.

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Article Name

5 Ways Augmented Reality Revolutionize The Manufacturing | ARP

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Integration of Augmented Reality In Manufacturing Can be Done in Various Stages Like Product Design, Production, Quality Control, Maintenance and Training. Essentially, AR is A Part of Industry 4.0 Revolution. These Real Success Stories Demonstrate The Same.

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Satish Kumar

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Augrealitypedia

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