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An immersive future is on the cards for a number of industries. Whether you’re walking into a 3D classroom or transporting yourself to a new dimension in the metaverse, AR/VR solutions are quickly seeping into everyday life.
Manufacturing is one industry continuing to benefit from immersive tech development. After experts predicted that over half of all manufacturing giants had used at least one form of VR aid in 2023 alone, industry-wide adoption isn’t far away.
In order to keep up with growing consumer demand, manufacturers are constantly finding ways to streamline all processes from training, to design and production. In the last few years, we’ve seen DB Schenker’s virtual forklift remotely train new recruits while Renault pioneers the future of automotive design with their digital twin system.
The question is, what’s next for VR in the manufacturing industry? Let’s have a closer look at the companies embracing immersive solutions in 2023.
On-the-job training
AR and VR are changing the way the manufacturing industry trains new recruits, with immersive tech ushering in a new era of remote onboarding and virtual training.
Specialised AR specs can project graphics, video guides and text-based instructions in front of trainees as they get to grips with a new piece of machinery.
Logistics giant DB Schenker is taking virtual training one step further by adding VR to the mix. In order to streamline the onboarding process for forklift operators, the company has introduced a virtual forklift simulation to their training room.
Using a VR headset, new recruits can experience a personalised forklift simulation that puts each user straight into the driving spot. The virtual tool replicates real-life predicaments, so employees quickly learn how to tackle tricky situations and practice safety measures before even setting foot in the warehouse.
“It is mainly an addition to traditional safety training. The system makes it possible to simulate dangerous situations that cannot be applied in real training. A person walking onto the path from a side corridor, for example," says developer Rob Kitzmann-Vreede.
After opening up the first virtual warehouse in the Tilburg Logistics Center, DB Schenker plans to fully automate their training process by 2025.
Digital twins
Digital design has evolved once again with the introduction of digital twins. As the manufacturing industry adopts more VR solutions, it’s becoming easier to design, test and monitor intricate product creations.
Using immersive technology, product designers can project a digital representation of a physical system, also known as a digital twin. These virtual twins, however, are more than just a 3D projection. All elements within the physical system, from the wires to its working lifespan, are mirrored and can be simulated in seconds.
Take automotive giant Renault as an example. Using a digital twin system, they’ve been able to streamline their vehicle design and production by introducing virtual versions of their motors to the engineering process.
Using digital rendering tools, Renault’s designers can quickly assess the quality of a car’s bodywork, from the appearance of glossy surfaces to your reflection in the glass.
Once designers sign off on product visuals, the digital file is sent to the engineers, where the real potential of a digital twin is put to the test.
“During this phase, engineers use a 3D copy of the entire digital twin for an immersive simulation to test, for example, bodywork aerodynamics, engine performance, gear management, or even air conditioning efficiency. Everything is put through its paces,” say developers at Renault.
Engineers can even place a virtual occupant in the driving seat and test the capability of the motor during crash simulations and realistic road driving scenarios. This is a step in the right direction for automotive health and safety, as models can be tested and tweaked before they are even produced.
Vision picking
One of the world’s leading logistics providers, DHL, is also using immersive technology to enhance their warehouse operations. After the ecommerce sector grew by over a third during the pandemic, speedy turnaround times for suppliers have become essential.
Introducing their new vision picking system, warehouse operators can now use smart glasses to digitally guide themselves around a busy storeroom and pick products in minutes.
Projecting a virtual map of the warehouse, AR glasses can speed up product picking and enhance employee vision. The pilot of the immersive aids alone increased productivity by 25% and significantly reduced human error.
“Vision picking enables hands-free order picking and greatly increases productivity. The technology significantly supports our staff and brings exciting value to our customers. However, this is just the first step in our innovation journey as we believe augmented reality will become relevant for even more supply chain areas“, says Business Unit Director Jan-Willem De Jong.
Fault-free assembly
Virtual reality aids continue to improve engineering efficiency. Using goggles that can virtually position engineers inside the product they are assembling can ensure a future of fault-free manufacturing.
Using Oculus’s newest depth and motion sensors, VR headsets can show trainees the inner workings of machines and virtually demonstrate how parts are connected and put into practice.
Lockheed Martin’s CHIL room is one of the largest VR-driven labs in the world and is used by the defence and aerospace company to streamline product design and manufacturing. In a collaborative environment, engineers can quickly analyse designs and test machinery prior to assembling the product.
“VR is now woven into the Digital Tapestry at Lockheed Martin, enabling a holistic approach to engineering at all stages of the product development lifecycle. At its core, the Digital Tapestry is about improving human interaction and decision-making,” says Lockheed Martin’s CEO, James D. Taiclet. “VR can take complex datasets and present them at a level of abstraction that allows a wider audience to participate in engineering decisions, including the technicians who build products on the shop floor.”
A virtual future for manufacturers?
Virtual reality in the manufacturing sector continues to hold a great deal of promise. On the back of covid forcing the sector to re-evaluate remote onboarding and warehouse operations, is it time for manufacturers to explore the possibilities of digital aids?
For designers and developers, an immersive future looks exciting. As digital twins streamline design, while VR labs cut production time in half, virtual reality has the ability to revolutionise the design and distribution process.
