AR Technology Implementation in Industrial Plants: Why Is It Growing?

The adoption of AR technology in industrial plants is accelerating rapidly—and for good reason. While it’s no surprise that AR and VR technologies are advancing every year, their increasing application in the enterprise sector stems from one key factor: they deliver tangible benefits and solid ROI. This practical value is driving their widespread adoption.

One of the key areas where Augmented Reality Manufacturing is making a significant impact is Remote Assistance and Digital Workflow. But why has this become so important and widely used? Let’s dive in.

Remote Assistance & Digital Workflow

A common challenge in modern production plants is frequent machine malfunctions. The costs and logistics of transporting experts to address these issues can be high, especially when multiple faults occur each year. Each expert requires transport and labor, which adds up costs quickly, particularly when considered annually. Additionally, machine downtime is costly, as it can slow or even halt production, leading to even greater losses the longer it persists.

The solution is Remote Assistance. This technology connects on-site technicians with experts remotely, allowing them to resolve issues efficiently. Using an Augmented Reality (AR) or Mixed Reality (MR) headset, the expert can see exactly what the technician sees in real-time, offering visual instructions, highlights, and additional guidance directly through the headset. This significantly reduces downtime and associated costs.

Unlike a regular video call, both the technician and the expert have real-time, easy access to information. The technician, wearing a headset or smart glasses, is hands-free and receives instructions and highlights directly in their field of view, allowing them to focus on the task without interruption.

Digital Workflow, on the other hand, is a solution that integrates and automates various processes in a production environment by leveraging the capabilities of Augmented Reality and Mixed Reality technology. It streamlines operations by providing technicians with real-time access to digital instructions, data, and insights directly in their field of view.

Using AR or MR headsets, technicians can view digital information overlaid on the physical environment, such as machine schematics, operational procedures, or safety guidelines. The workflow is continuously updated, ensuring that they always have the most current information, enhancing decision-making, and minimizing errors.

The digital workflow is also vital for employee training, providing real-time, overlaid information in their field of view. New technicians, for instance, can learn to operate complex machinery by following step-by-step holographic instructions. This method speeds up the learning process, reduces reliance on physical training materials, and enhances retention through interactive, hands-on experiences.

Digital Twin in Augmented Reality Manufacturing

Let’s begin with the basics – a digital twin is a virtual representation of a physical entity, system, or process that mirrors its real-world counterpart. This technology uses real-time data and historical information to create a dynamic model that accurately reflects the behavior and state of the physical object throughout its lifecycle.

Augmented Reality enhances this by overlaying digital information from the digital twin onto the physical world. For example, technicians can wear AR glasses that project maintenance data directly onto machinery, providing contextual details such as operational status or maintenance history.

AR and VR also provide immersive training experiences, allowing workers to interact with virtual models of equipment and processes without the risks associated with real-world operations.

Another key area where digital twins are valuable is in design and prototyping. Engineers can visualize how components fit together in real-time while referencing digital twin data for specifications, reducing errors during assembly and improving collaboration among team members.

These advantages lead to numerous benefits for manufacturers, including improved decision-making, increased efficiency, enhanced safety (such as through training), and cost savings.

Mixed Reality Training

Mixed Reality can create immersive learning experiences across various sectors, such as assembly training and safety compliance. It also enables co-located experiences, allowing multiple people to interact with the same virtual objects or share the same virtual environment in VR. But the question remains—are these technologies as effective as they appear?

Traditional training often involves significant costs, including travel, materials, and the need for physical presence. Mixed Reality can drastically reduce these expenses by enabling remote access to training sessions. Research shows that using VR for large-group training can be up to 52% more cost-effective than traditional methods.

In fast-paced manufacturing environments, time for training is limited. Mixed Reality accelerates learning—studies show that employees trained in VR complete tasks up to 40% faster than with traditional methods. This increased efficiency is essential for meeting production timelines.

Training in hazardous environments involves inherent risks. MR allows employees to train safely by simulating real-world conditions without exposing them to actual dangers. For example, they can practice emergency procedures or equipment handling in a controlled, risk-free virtual environment.

When it comes to Mixed Reality training in industrial VR, selecting the right tools is essential. Choose between a fully virtual environment or Mixed Reality based on your specific training needs. Ensure that both hardware and software align with your objectives to achieve the best results. For hardware, the Pico G3 headset is an affordable, versatile option with broad software compatibility.

As for software, you have several options. You can use ready-made VR apps for training. Kognita offers 30 in its portfolio, including VirtualSpeech for building soft skills, 4Help VR for first aid training, Baker Scaffolds for Montage Training, and others like Trenching and Excavation Safety, Electrical Safety, and more.

Alternatively, you can create custom training programs using specialized platforms. Kognita, as the official distributor of the 3D Frame platform, provides access to CAD and BIM files, hand-tracking integration, and an AI assistant. If you need a tailor-made solution, Kognita also offers development services to create custom training apps from scratch.