Manufacturers are facing changes on many fronts. The rise of technology has given rise to the Industrial Internet of Things (IIoT), changing the appearance, systems and processes of modern factories. At the same time, global competitive pressures and a changing workforce require new approaches to employee training and a reexamination of workers' roles in factories. Still, the drivers of manufacturing have not changed: Since the Industrial Revolution, manufacturers have been pursuing faster production, higher quality, and lower costs through the adoption of technology. Now, they must figure out how to turn these challenges into opportunities and do so by embracing the digital wave. In this environment of tight deadlines, higher customer expectations and increasing competition, if manufacturers want to thrive, they must be clear about where to invest in emerging technologies.
1. Demand for fine craftsmanship and high-end technology manufacturing
While robotics can help improve operational speed, quality, consistency, and efficiency, manufacturing of delicate processes still presents some challenges. For example, many manufacturing industries still rely on printed data and work instructions, which means operators need to leave their workstation to view this information, which can lead to operational errors and production inefficiencies. In addition, when a problem arises and needs to be solved, remote experts need to be relied on, and they may need to go to the site in person to solve the problem, which will also cause additional time and cost. In addition, training far away from the production point is also a challenge. Employees need to spend extra time and cost to receive training, which will also affect production efficiency.
Therefore, in order to solve these problems, the manufacturing industry needs to consider adopting more advanced technologies and solutions. For example, digital process simulation and virtual reality technology can provide real-time guidance and training, allowing operators to obtain accurate and detailed information at the work site, reducing operating errors and improving production efficiency. In addition, the introduction of intelligent monitoring systems and data analysis technology can help manufacturers monitor abnormalities in the production process in real time, discover and solve problems in a timely manner, and improve quality and efficiency.
2. Increasingly prominent competitive pressure
While industrial manufacturing in the Western world has modernized in recent years, many industries have been facing a downward trend. More and more factories are being moved overseas to take advantage of areas where labor and raw material costs are lower. However, as the geopolitical landscape changes, this trend may reverse.
Changes in the geopolitical landscape may exacerbate skills gaps and accelerate the need for new employee training. Manufacturers will have to quickly adapt to new industry regulations and trade requirements that impact their distributors and suppliers. Such changes are bound to bring a series of new challenges to manufacturers.
To address these challenges, manufacturers need to take a number of measures. First, they should invest more in employee training and work to close the skills gap. By providing appropriate training and development opportunities, manufacturers can help employees adapt to change and acquire the new skills they need. At the same time, manufacturers should also seek new market opportunities and reduce dependence on specific regions. By opening up new markets, they can diversify risks and mitigate the impact of geopolitical changes on their supply chains. In addition, manufacturers should also strive to improve production efficiency and innovation capabilities. By adopting advanced technologies and processes, they can improve production efficiency and enhance competitiveness, thereby gaining an advantage in fierce international competition.
3. Long-term training of technical talents
Classroom-based manual training is often lengthy and involves passive learning that involves reading technical manuals, perusing program documentation, receiving verbal instructions, watching videos, and listening to demonstrations from instructors. However, for younger employees, who are accustomed to getting the information they need with a few clicks, they are less likely to sit down and receive traditional coaching sessions. Therefore, active AR on-the-job training proves to be effective as it improves training retention and allows new employees to contribute to the productivity of the factory while receiving training. Online training platforms, augmented reality technology, and simulated operations provide an interactive and engaging learning experience. Employees can better understand and apply the knowledge and skills they have learned by participating in practical and simulated work tasks.
4. Manufacturing applications of AR glasses
1 Complex assembly
Hongke AR solutions are ideal for complex manufacturing processes involving variations and lengthy lists. On the assembly line, smart glasses wearers can use voice commands to view step-by-step instructions, diagrams and other guidance information superimposed on the actual assembly they perform. Different voice commands or barcodes can even bring up unique assembly instructions for custom orders. Hands-free instructional support directly in the worker's field of view helps speed production, reduce error rates and improve safety. Employees are able to work faster and with top-notch quality, eliminating minutes and hours of assembly time, and often even avoiding repetitive motion injuries and error-induced accidents. Computer vision with visual recognition technology provides another layer of quality control as managers verify each step by “looking” through built-in cameras worn by workers.
2 Maintenance and repair
By providing hands-free information, convenient real-time remote support, and using artificial intelligence to detect problems to improve equipment repair services, engineers can view real-time machine data and 3D models, detailed instructions of back-end systems or video tutorials overlaid on real machines. . The technology is also able to "listen" for unusual sounds, such as whistling or high-pitched sounds, and automatically create relevant maintenance commands. M-series smart glasses can be used to live-stream a manufacturing technician's situation to a remote expert, who can see the technician's line of sight and guide him correctly through words on the correct maintenance procedures. Reduced travel and faster problem resolution can reduce downtime, save millions of dollars, and extend the careers of the industry’s most experienced workers.
3 quality inspection
Workers use AR smart glasses that integrate with the manufacturer's quality management system (QMS) to pull checklists, verbally confirm actions, take audio notes, call other technicians and instantly upload their findings.
The heads-up, hands-free form factor allows quality inspectors to move around and conduct hands-on testing. Instead of filling out forms or typing reports, they can use the smart glasses’ cameras to objectively record issues as they are discovered and update their QMS in real time to ensure work is not duplicated and defects can be resolved faster. Factory workers can use AR to help find defects, and artificial intelligence and computer vision to assist human decision-making.
4 Industrial training
Compared to training through manuals or videos, AR training is generally considered a more intuitive and effective learning method. Augmented reality programs can help minimize training costs for manufacturers, allow for faster on-the-job training, and leverage the knowledge of experienced workers through online and first-person training.
AR can even allow manufacturers to integrate training directly into production activities. Wearing smart glasses, new employees can be instantly deployed to guide them step-by-step through operations and overlay visual aids on the parts and equipment required for assembly and operation. Senior employees can use smart glasses to record videos of complex assemblies, creating valuable training material that often shortens the learning process for new employees.
AR smart glasses are already being used by major automobile manufacturers. The automotive industry is a good case study: the high variability on modern automotive assembly lines presents classic manufacturing challenges that automation cannot solve alone. The complex exception handling processes involved in industries such as automotive assembly require a smart device, and AR smart glasses fit the bill, enabling workers of all skill levels to respond flexibly to changes.
