Quality assurance How Augmented Reality is revolutionizing the manufacturing industry

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Augmented Reality (AR) enhances the real environment with virtual information and is therefore suitable for many application areas. A showcase at the Hannover Messe illustrated how AR improves processes on the shop floor and serves as support for employees.

Björn Manderbach, Director, Delmia Industry Consulting, Dassault Systèmes; Dr. Darko Sucic, Senior Director, Industry Consulting, Dassault Systèmes

More and more companies are discovering the application possibilities and the advantages of Augmented Reality (AR) in the industrial sector. Translated, the term means "enhanced reality" – and it is exactly this that can be used for many task areas. With AR, real scenes can be supplemented with virtual information, while users move freely in space – for example, in a factory hall. The actual environment is perceived fully and without restriction. To retrieve additional virtual information, it is enough to be equipped with a tablet PC or a smartphone. The camera image of the device is supplemented with the desired details – like an extended viewport. A special advantage is that the portable device can be taken anywhere – wherever the place of use may be. Therefore, AR is particularly suitable for application fields where freedom of movement is necessary, such as in assembly, quality assurance, or maintenance.

Virtual Reality blocks out the environment

In contrast, Virtual Reality (VR) obscures the environment and typically presents an alternative, new environment to the user. For this experience, wearing goggles that encompass the eyes is necessary. However, this significantly limits mobility, and free movement is not possible for safety reasons. VR is particularly useful for applications such as reporting and in special rooms.

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The third variant is called Mixed Reality (MR) and is a combination of AR and VR. Here, natural perception is mixed with an artificially created reality. Like with the use of VR, the user is required to wear goggles. The lenses of the goggles are partly transparent, allowing users to always have a view of the real environment. This makes the use of MR much more flexible in application than that of complete Virtual Reality. However, glasses suitable for MR are currently very expensive to purchase and sensitive to use.

Wide application fields for Augmented Reality

Augmented Reality is often the tool of choice for manufacturing companies due to its flexible application possibilities. This technology is particularly suitable for assembly and quality assurance or maintenance. The tasks and work steps in these areas are often very complex - as are the work instructions for the executing professionals. Unfortunately, theoretical content does not always help in practice. With the help of AR, employees can be guided directly in the work environment. Individual work steps can be projected onto a component or a machine so that it can be directly understood what needs to be done. This is possible from the first action to the completion of the order - regardless of company size and industry.

Machine maintenance and servicing

Especially in mechanical and plant engineering, Augmented Reality can simplify many work processes. Machines are often custom-made and exhibit a high variance – particularly in the German medium-sized sector, orders are very customer-specific. Moreover, skilled workers are usually under high time pressure. Errors must therefore be quickly identified and corrected. For example, to access a defective motor, several components often need to be dismantled and then reattached after the repair. With the help of AR, it can be displayed which component must be removed first – step by step, until the work order is completed. Small and medium-sized enterprises (SMEs), which until now did not have the corresponding detailed know-how or the internal specialists to carry out complex maintenance themselves, can particularly benefit from this. AR support reduces complexity – and thus the dependence on external support.

Analyze the machine's structure in advance

The use of AR is also advantageous for maintenance personnel. They can specifically prepare for customer appointments because they can precisely analyze the structure of the machine in advance thanks to the digital availability of data. This way, they know beforehand which components and tools are needed. Redundant trips and appointments are eliminated.

Quality assurance

AR also has great potential in quality assurance, for example, in comparing actual and target states. This can determine whether the construction status matches the planning, whether all parts have been correctly assembled, or whether improvements are necessary. The system quickly scans to check if everything is correct, for instance, if all components have the correct dimensions. The construction data are superimposed on the real object like a kind of template, and any deviations are detected. Time-consuming manual checks can thus be minimized. Parts supplied externally can also be quickly inspected using this method.

Internal quality audits during production can also be carried out and improved with the help of Augmented Reality. If the system registers an error, it can be displayed at every step of the value chain. Thus, potentially every skilled worker in the manufacturing process becomes a quality inspector, and defects can be eliminated long before the final quality control. If errors occur more frequently, direct transmission to product development is possible to identify deficits in the original product.

Digitalization you can touch

Technologies like Augmented Reality provide employees with tremendous work relief. Cumbersome searching in often outdated documents is eliminated, and complex work orders can be completed quickly and easily thanks to digital support. Thus, the often abstract concept of digitalization becomes truly experiential for users. This not only promotes competence but also satisfaction and acceptance of new technologies.

In harmony with artificial intelligence

Technical innovations like artificial intelligence (AI) further support the capabilities of AR, for example, through intelligent camera systems. Computer Vision is a field within AI that enables computers and systems to extract meaningful information from digital images or other visual inputs. This is the basis on which the interplay of Computer Vision and AR operates. An industrial camera acts as an interface between the real and digital world by capturing the environment, and the AI behind it analyzes the image data. This enables the overlay of virtual information, for example, without markers, as information such as edges is recognized.