Augmented reality (AR) has long ceased to be just a novelty and is becoming a serious aid in manufacturing. Unlike virtual reality, which creates a fully digital world, AR adds digital elements to our real-world environment in real time — this can include text, images, or 3D models.
AR is often used in assembly processes, improving assembly accuracy and reducing errors. The technology also facilitates working with collaborative robots (cobots), making operators’ jobs easier.
Companies like General Electric use augmented reality to enhance equipment maintenance efficiency. Workers see diagrams and instructions in front of them, allowing tasks to be completed more accurately and 34% faster. Boeing uses AR for assembling complex airplane components — engineers receive visual guidance in real time, reducing assembly time by 25% and defects by 40%. BMW and Volkswagen also employ AR for employee training and design processes. Detailed 3D models of vehicles and components help workers understand designs faster and accelerate development.
However, despite their simplicity and accessibility, AR glasses that overlay virtual instructions on real objects have not yet become a standard tool in manufacturing.
Let’s refer to an Australian study where researchers investigated the reasons for this and examined how AR technologies are integrated into production processes. Notably, Australia has a slow rollout of Industry 4.0 technologies in its industrial sector.
AR is an inexpensive technology that simplifies complex industrial processes. However, challenges arise when integrating this technology into workflows. Researchers evaluated how AR glasses with digital work instructions, cobots, and video consultations affect the quality and speed of electrical installation tasks.
Cobots (collaborative robots) are designed to work alongside humans. Unlike traditional industrial manipulators, which typically operate in isolated zones for safety reasons, cobots interact safely with people while performing tasks nearby.
Cobots are equipped with sensors and software that allow them to detect human presence and reduce speed or stop when contact occurs. Installing and configuring cobots is usually easier and faster than traditional robots.
The experiment involved 36 heavy industry workers, mostly shipbuilders, aged 18 to 62. All participants had manufacturing or construction experience, and 90% held higher education degrees.
Participants performed wiring installation in an electrical cabinet, receiving digital instructions and holograms via AR glasses (Hololens 2). They could communicate with a remote mentor via video calls. After completion, the cobot checked the assembly quality using machine vision.
On the System Usability Scale (SUS), AR glasses scored 69.8 ("acceptable"), and in combination with a cobot — 79.2 ("very good"). Interestingly, working with both the cobot and glasses was easier and more convenient than using glasses alone.
Physical workload using AR glasses was low (25.8), but mental workload was higher (37.1) due to the need for concentration and processing information. Some participants experienced discomfort while using the glasses, but it did not impede task completion. 48% reported issues with gesture recognition, and 25% noted a limited field of view.
97% of participants felt safe around the moving cobot. Most found the system intuitive after some use.
Main concerns involved the cobot camera’s accuracy and precise marker placement. Participants suggested improvements in navigation and interface for better usability. Some identified barriers to AR adoption, including cost, stress, and training requirements.
The study demonstrated that integrating AR glasses and a cobot can significantly improve the accuracy and efficiency of electrical installation tasks, despite some technical and ergonomic issues. Participants noted that the system, including AR glasses and a cobot, requires basic skills, minimal effort, and offers substantial functionality.
The main challenge with AR glasses is the high mental load from processing multiple information sources. However, all participants successfully completed the tasks with minimal training, potentially reducing barriers to implementing the technology in manufacturing.
We can make an interim conclusion as to why AR glasses are not yet used in every production environment. It turns out that they are not a “magic solution” by themselves. Glasses only work effectively in tandem with a human, and it must be convenient for them.
A user-friendly interface is required, interaction with virtual objects must be optimized, ergonomics improved, and at least a basic training course provided. In other words, preparatory work is necessary, which not every production facility is ready to perform.
No one denies that augmented reality is highly promising. It has the potential to transform manufacturing, significantly increasing flexibility, responsiveness, and efficiency. However, AR does not replace humans — it assists them. And it only works effectively if the human is motivated. Thus, AR does not solve the workforce shortage problem but can help mitigate its impact.
