Augmented Reality (AR) is on the rise in the aerospace industry as more manufacturers look to optimize their operations and prevent costly errors. Since 2020, companies in the sector have been adopting AR technology in record numbers. What can AR do for aerospace manufacturing? The two main applications currently are training and maintenance. AR provides useful training support for technicians and engineers. Likewise, it can speed up maintenance processes and reduce error rates.
The Role of Augmented Reality in Aerospace Training and Maintenance
A Growing Role for an Emerging Technology
Even though AR has been around in some form for decades, it’s seen a recent rise as the technology matures. Originally, AR systems were used by chief engineers and designers in R&D and prototyping. In large part, this was due to the high cost of AR systems. AR was only justifiable for the small number of staff that could yield the most value from the high investment. Today, however, AR is much more affordable, leading to an expanded role.
Over the past decade, AR began to take on an important role in training. AR’s intuitive presentation of information allows workers to learn autonomously without a supervisor hovering over their shoulder. However, in the last few years, AR has gone beyond training and is now actively used in maintenance and manufacturing operations in many industries, including aerospace. Why is this technology ideal for these applications, and how can you implement it effectively?
Augmented Reality Makes Training Faster and More Efficient
A meta-analysis of studies related to AR found that the global pandemic thrust AR into the spotlight as a useful tool for remote workers. Starting in 2020, the number of AR studies tripled and continued to grow in the following years. However, AR is even more effective in in-person environments, which explains why companies have only continued to invest in the technology in recent years. Training has been the primary focus of AR, and for good reason.
AR systems use cameras to analyze what an individual is looking at, and then they present relevant information to the user. Suppose an assembly worker is learning to install a window on an aircraft. Upon looking at the mounting location, the AR display could circle bolt holes and enumerate them to instruct the worker on the correct bolt pattern to follow. Rather than try to memorize the correct procedure, the worker follows instructions that quickly become second nature.
Autonomous Learning With AR
With AR providing instructions, workers can gain knowledge and experience without as much one-on-one training from more experienced staff. While supervised training is still beneficial, AR ensures that everyone gets the same training experience. AR systems can be programmed to provide step-by-step instructions for every process in your operations. Audio instructions can even be delivered to complement visual feedback. It’s even possible to integrate voice recognition so that workers can casually ask for clarification
AR has been evaluated next to VR systems and studies find that AR is more effective at training. While VR can provide excellent simulations, AR’s advantage is that it integrates learning with real-world practice, making lessons stick. In addition, AR provides a consistent experience, which helps to solidify learning as workers repeat tasks following the exact same procedure.
Faster, More Accurate Operations
In both training and maintenance, technicians and engineers need to rely on manuals and procedures to perform their tasks effectively. However, this often means lugging around a massive binder. While printed manuals can still be useful, they’re unwieldy and are not always designed well. Ultimately, printed materials slow down operations compared to using AR. Simply being able to see instructions and act on them means less time consulting manuals and more time getting work done.
Within the aerospace industry, a study comparing performance with paper manuals and AR systems found that AR systems saved 10-15% off task completion time. More importantly, the AR cohort had no errors at all, while paper manual users typically had one or two procedural errors. This study used NASA standards to evaluate the participants’ performance and found that AR would be the most effective method for training and maintenance.
Affordable AR Implementation
AR is more affordable than ever. Microsoft HoloLens 2, one of the leading AR solutions, currently costs around $3,500 per unit. Its capabilities make it well worth the investment. However, even more affordable options are available today using Android phones. There are low-cost headsets that can turn a smartphone into an AR device. In this format, AR could cost less than $1000 per unit.
The bulk of the cost of implementation comes from programming your AR devices to guide your team through your processes. As the aerospace industry is highly specialized, you may need to develop custom programs for your processes. However, there are also third-party vendors with turnkey solutions for specific assembly processes or machine use. By working with an experienced digital transformation expert, you can acquire or develop the right AR tools for your operations.
Transforming Your Aerospace Operations
Implementing AR is just one step towards digital manufacturing. Besides using the latest technology like AR in your operations, you also need to digitize your back office, capture data from your manufacturing processes, and leverage business and industry intelligence platforms to derive insights from your data. Together, these Industry 4.0 tools combine to empower your company through higher efficiency and reduced long-term costs. Nevertheless, every business requires a personalized approach to their digital transformation.
To ensure your company’s transformation goes smoothly and delivers the results you’re looking for, work with experienced professionals. Contact SAAB RDS to schedule a meeting with one of our Industry 4.0 experts.