As the factory environment continues to evolve beyond this pandemic, AR-enabled programs will deliver transformational results to manufacturers and industrial enterprises.
When augmented
reality (AR) was first introduced in 1992, the primary use
cases for the technology involved military or gaming applications. Nearly 30
years later, many enterprises in the industrial sector are turning to AR technology
to aid in the remote training, and up-skilling and re-skilling of their
workforces and are reaping the benefits.
Workforce
Shortages in Manufacturing
Over the past five
years, manufacturers have reported a growing shortage of qualified skilled
laborers. These include positions such as machine technicians and worksite
managers. The workers filling these jobs must not only be able to efficiently
perform difficult and stressful tasks onsite, but also meet safety requirements
as they are mandated by OSHA and other regulatory agencies.
See also: Augmented Reality is ‘IoT for People’
In September
2019, the National Association of Manufacturers claimed that 522,000
job posts went unfilled – a record number. The lack of unskilled laborers will
only worsen, as The Manufacturing Institute anticipates 2.4 million
unfilled jobs over the next decade. The U.S. administration has recognized the
need for additional skilled industrial workers and has committed to training 1.86
million workers in the next five years. However, mid-size and regional
manufacturers need to increase the size of their workforce now, not in five
years.
To lessen the
skills gap in the years ahead, new hires will need to be rapidly trained on the
machinery and processes they will be overseeing, as manufacturers aim to resume
full-scale operations immediately and take advantage of their full workforce.
In addition, returning workers will potentially need to be trained to manage
new digitized and automated technologies that they didn’t interact with prior
to the pandemic.
Using Augmented
Reality to Train Workers
This rapidly
changing labor landscape is forcing the industrial sector to implement AR
technology. AR enables manufacturers to digitize their workforce training
programs – allowing them to train their employees faster and more efficiently
than would otherwise be possible.
New workers in the
manufacturing industry that need to train to learn new and different equipment
can leverage heads up displays to follow along with an experienced trainer. For
example, a new worker can learn different or new manufacturing processes via an
AR headset. Trainees can follow step by step instructions for any necessary job
functions with the headset overlaying the processes with the manufacturing
equipment and real-world environment. This allows them to see how to apply the
instructions to the correct parts of the machinery in real-time.
The
standardization of training programs through digitization also ensures each
worker receives the exact same level of training. Further, manufacturers will
not have to be concerned with accidental miseducation of trainees that could be
caused by an instructor oversight – such as forgetting to mention a small but
important piece of the training. When dealing with heavy equipment and
machinery found in manufacturing shop floors, missing even the smallest
training detail can result in a workplace safety issue.
Using AR
During COVID-19
In response to
COVID-19 and the associated stay-at-home mandates, many manufacturers have been
forced to send the majority of their floor workers home. Many of these
manufacturers cannot continue production without
onsite personnel to carry out day-to-day operations. On the other hand,
they cannot violate mandates regarding social distancing and non-essential
business closures.
The COVID-19
pandemic has also forced non-essential manufacturers to shut down operations.
At the same time, the need for PPE, ventilators, and masks skyrocketed as
coronavirus infections rapidly spread at the start of the pandemic.
Non-essential manufacturers who have been forced to shut down their facilities
to comply now can become an essential business by pivoting operations to
support the manufacturing of these necessary items. AR technology enables
manufacturers to rapidly shift operations by quickly re-skilling and
up-skilling their workforce to produce these much-needed items, while also
ensuring they maintain the high standards required of the products.
In order to
remain operational and maintain remote worker productivity, an increasing
number of manufacturers are implementing AR-enabled remote assistance
solutions. AR-enabled remote assistance allows detailed interactions between
onsite personnel and offsite experts to take place. In many situations, a
simple phone call might suffice to diffuse any onsite issues or troublesome situations.
However, this is not always the case.
By combining AR
applications with a live video feed of the onsite worker’s situation and
environment, a remote expert or technician with superior knowledge can observe
situations in real-time and provide specific, detailed instructions on how to
perform the task at hand. Further, because AR uses video-based interactions,
the onsite worker has no trouble understanding the expert’s advice because it
will be demonstrated, virtually, right before their eyes.
3D spatial
notations on touchscreen devices can be layered over real-time video feeds to
highlight which specific machine or application components require servicing or
attention. For example, say a worker has trouble with a machine overheating on
the shop floor. If they are new to the role, they may have no experience
whatsoever with that machine and how it functions. Thanks to AR, the offsite
expert can not only explain but also show exactly what the new worker
must do to fix the machine.
AR technology enables
the rapid training of the manufacturing workforce, as well as the detailed
communication between onsite technicians and offsite experts. These efficient, modernized,
and digitized training programs will enable manufacturers to enhance the shift
to flexible production models. As the factory environment continues to evolve
beyond this pandemic due to technological, social, and regulatory changes, AR-enabled
programs will continue to deliver transformational results to manufacturers and
industrial enterprises.
