The “smart factory” is becoming increasingly important in modern day-to-day production. The innovative concept, designed to continuously collect, exchange and analyze data, represents a major opportunity for the manufacturing industry to grow productivity, reduce costs, enhance efficiency and much more. Despite this, the actual adoption of smart factory technology is still in its early stages with only 4.5% considering their factories to be “very smart,” according to a survey . One technology that has the power and potential to significantly enhance operations at factories is augmented reality (AR).
With AR, frontline workers can translate processes into assisted, augmented reality workflows where everything happens right in the worker’s field of vision, increasing productivity, decreasing error rates, improving quality, and saving costs. Hyundai Motor Company is an example of a manufacturer that is utilizing AR in their Singapore facility. The company has have a holistic smart factory that interconnects humans, robots and logistics, with the help of AR and artificial intelligence capabilities to support assembly, maintenance, quality management, logistics and workforce training. With the company’s transition to a smart factory, they have improved workflow, quality control, efficiency and onboarding of workers. How do organizations like Hyundai do it?
Read on to learn how AR can pave the path to your smart factory.
Step 1: Understanding what it takes to build a smart factory
Before diving into AR implementation, it's essential to understand the specific needs and constraints of the manufacturing environment. One of the most significant challenges to implementing a smart factory strategy is a culture that resists change. For successful transition to a smart factory, information technology (IT) and operational technology (OT) must integrate seamlessly. IT managers wanting to implement new digital tools in a factory must not only have a deep understanding of digital solutions, but also of what’s important to plant managers. They need to understand both realms, their differences, and commonalities.
Once these dynamics are sorted, you can shift the focus to the tech that enables smart factories.
Step 2: The role of Augmented Reality (AR)
AR plays a crucial role in the path to smart factories by enhancing the capabilities of frontline workers. And the industry is aware of its power–in fact, in a survey, AR was among the top technologies, with 62% of respondents stating they are planning to implement it by 2026. Integrating AR in the manufacturing process begins with establishing robust remote asset management. With the right tools, you can bring all the assets of OT equipment and devices into one dashboard to manage them remotely. From there, you’ll be able to see all your inventory–both IT and OT hardware assets–and manage connectivity to troubleshoot, should any technical issues arise.
Digitalizing manufacturing means support centers must be more agile and responsive in the event of a disruption, so a secure solution that provides access and control of machines on the factory floor without the need for sending technicians on-site is critical. This ensures technical teams can gain access to designated devices in an instant and it makes the transition to smart factories and using AR much smoother as all data is already digitized.
Step 3: Considering your workers’ needs
Consider an AR solution that provides frontline workers with everything they need to succeed, such as real-time, dynamic instructions directly in their field of vision. This technology makes workers more efficient and productive by eliminating the need to reference physical manuals or seek supervisory assistance for routine queries. The great thing about wearable technology is that it keeps the hands of workers free and available to do what they do best–it provides them with a truly hands-free mobile experience that enhances efficiency and reduces error rates. However, wearables aren’t one size fits all. It’s important to select a solution that aligns with your enterprise’s requirements and your specific use case.
There’s an array of different options for smart glasses, including AR, virtual reality (VR), mixed reality (MR), binocular and monocular, to name a few. A solid pair of modern smart glasses for industrial industries will typically feature a rugged yet light-weight design, high-res camera and flashlights, a durable battery, various mounting options, Wi-Fi, Bluetooth, a flexible non-obstructive display, and more.
Step 4: Realize the benefits of your Smart Factory!
Once you’ve rolled out the technology, it’s time to implement it and train the workers who will be using it. Luckily, a robust AR solution will typically drive the technical implementation with workshops and training–using the hardware–individualized to your needs and workers to ensure a smooth rollout. It’s also possible to seamlessly integrate into existing systems to ensure real-time data and no waiting time. And now for the best part: enjoy the array of benefits a strong AR solution brings. With AR implemented in your factory, you can:
- Create detailed, step-by-step instructions and other necessary content that workers can access hands-free through their device, reducing the need for extensive manual training and supervision.
- Digitalize paper-based processes and procedures running on outdated hardware.
- Do measurements and take pictures to document task completion.
- Eliminate the risk of distraction as there will be no more switching back and forth between different devices or media.
- Quickly create and dynamically update workflows to adapt to unforeseen or on-the-fly process changes and send them out to the workforce in real time.
- Easily scale solutions by replicating and adjusting workflows to other sites as needed.
- Significantly shorten training times to flexibly deploy new staff.Be one step closer to operating as a true smart factory.
With success stories from the likes of Hyundai, it’s clear that AR is revolutionizing the manufacturing industry with enhanced operational efficiency, reduced error rates, and increased productivity. Digital transformation across the manufacturing sector is an ongoing process and AR integration is just one step in the right direction. Implementing smart factory technologies–such as new robotic elements, ambient sensors, performance monitoring tools, and servers–makes for an increasingly complex tech stack to manage and maintain. And that’s not to mention the employees trying to upskill and adapt, while still being confronted with the day-to-day challenges of production.
But the adjustment will be worthwhile as transitioning to a smart factory has many benefits including improved productivity, safety, sustainability, product quality and customer service. Embracing smart factories is not just a step towards modernization, but a strategic move toward building resilient and forward-thinking manufacturing operations.
