Inglobe Technologies

Tag: industrial augmented reality

  • [Case Study] How ABB managed corrective maintenance with Augmented Reality

    [Case Study] How ABB managed corrective maintenance with Augmented Reality

    ABB is a Swiss Swedish multinational company operating in robotics, energy and automation, with a global turnover of 28 billion dollars. For some years the management has decided to start a series of projects in the Industry 4.0 field to test the most promising technological innovations for the Manufacturing sector, including an Augmented Reality project to improving how corrective maintenance was handled.

    Inglobe Technologies has been involved in an Augmented Reality project aimed at testing the usefulness of the technology in some maintenance processes, in particular corrective maintenance, to allow operators to promptly intervene on certain types of faults without involving specialized maintenance personnel and in order to reduce downtime.

    The activities carried out

    The project had three phases: one for analysis and planning of activities; one for the execution of the project; the last one to evaluate the results.

    During the planning phase, the Inglobe team and the ABB engineers of the Frosinone plant identified the most sensible use cases on which to develop the pilot project, identifying a series of equipment and technical procedures to be digitized.

    The next phase saw the actual realization of the project with the following activities:

    • Creation of 3D targets for object recognition and tracking
    • Creation of digital operating procedures with the HyperIndustry platform
    • Customization of the mobile app for mobile devices
    • Deployment and Training

    The operating procedures, organized in sequences of non-linear steps, therefore including branches, were created with the HyperIndustry industrial Augmented Reality platform, using a visual workflow, without any need for coding.

    Finally, the procedures were published and made available on the mobile application, which in this case ran on an Android tablet. ABB staff has been trained to use the mobile application autonomously.

    In the last phase of the project, ABB management carried out assessments on the main KPIs of the project in order to evaluate the quality of the technology.

    Challenges of the project

    The implementation of projects concerning new technologies, and therefore also Augmented Reality, in a factory, is almost always challenging since they introduce various new elements.

    Among the challenges of the project we can mention:

    • Choice of the most appropriate device
    • Choice of the most appropriate use case

    The choice of a device in an Augmented Reality project requires careful and thoughtful assessments as the success or otherwise of the initiative may depend on this single variable. In the case of ABB it was required that multiple operators could use the same device and it was not required that at the time of use the operator had both hands free.

    These initial requirements, and the due assessments in terms of the impact of hardware on the project costs, prompted us to opt for a mobile device rather than a smartglass, also based on the battery life compared to the duration of the work shifts.

    For the choice of the use case, ABB has assessed on which machines the stoppages were more frequent and could be solved with low complexity interventions, such as the replacement of small accessories. The choice fell on a machine that is part of the assembly process of industrial switches. The reason is that one of the most frequent causes of machine downtime was the breakage of the screwdriver insert, a component that can be easily replaced by line staff without requiring the booking of the intervention of a specialized maintenance technician.

    The results of the corrective maintenance project

    Thanks to the Augmented Reality pilot project to support maintenance, ABB has managed to provide an easy-to-use tool to its operators, allowing them to carry out a first level maintenance with the Augmented Reality app, which acts both as an instruction manual (and therefore training tool) and troubleshooting tool, supporting operators to intervene and repair the fault.

    The ABB plant in Frosinone has continued to implement Augmented Reality in its industrial processes by involving staff in this transition from paper to digital and by adopting the HyperIndustry platform to extend the technology to other production lines of the plant.

  • Inglobe presents an Industrial Augmented Reality case study with Huawei

    Inglobe presents an Industrial Augmented Reality case study with Huawei

    When people think of improving efficiency in a business with digital technology, they often have an image of a robot on an Industry 4.0 assembly line. In practice, tasks involving people are also being performed more smoothly and rapidly with the help of technology.
    This case study describes a project that Inglobe has delivered for Huawei Technologies to provide its technicians Industrial Augmented Reality tools to carry out common tasks more efficiently.

    Background of the project

    Installation and maintenance of IT equipment can be complex. The outcome of a work order is affected by a number of issues. The technicians have too many procedures to remember and even with the best documentation, reading text and looking at images of a product can be misunderstood or time consuming. Extra time must be taken to avoid errors, which leads to inefficiencies in the performance of assigned tasks, security problems and, ultimately, higher costs.

    Working with Huawei’s Technical Documentation Innovation team, Perey Research & Consulting invited Inglobe Technologies to provide an appropriate solution for developing AR-enhanced installation and inspection instructions through its HyperIndustry platform.

    The HyperIndustry platform is the basis for delivering targeted applications to support field technicians during installation, assembly and maintenance of some enterprise-class equipment, improving their performance. This project focused on the SUN2000-KTL inverter, a device that converts DC power from photovoltaic power systems on commercial rooftops and in large power stations into AC power and feeds it into the power grid.

    The goal of the project was to assess how HyperIndustry – Inglobe’s Augmented Reality platform for Industry 4.0 – could improve the installation and maintenance processes of Huawei’s SUN2000-KTL product.

    The challenges of the Industrial Augmented Reality project

    The project presented a series of technical and organizational challenges to the partners. First, the team members collaborating on the project were in different regions of the world (US, Europe and China) and all development had to be performed remotely. The Inglobe technical team never had direct access to the devices on which the project was to bring value. Nevertheless, all the tracking and testing operations were successfully completed on schedule.

    The installation steps tested for AR-enhancement are complex. Huawei has published videos and images to support the technician, as well as specialized tools. Each step must be completed in order for the correct installation.

    Further, Huawei required that the application rely entirely on natural feature tracking. Finally, the solution needs to work outdoors, in highly variable climatic and lighting conditions in which the SUN2000 inverters must be installed. Without use of any marker and relying solely on 3D models based on photographs, Inglobe Technologies’ 3D tracking component delivered excellent results on systems mounted on building rooftops.

    How the AR experience is structured

    AR-assisted procedures developed by Inglobe Technologies for Huawei focus on installation and maintenance instructions of SUN2000 inverters in photovoltaic systems installed outdoors.

    The AR experience was created rapidly based on a detailed storyboard and using the HyperIndustry platform, an Experience Management System for Industry 4.0. The platform compiles all the necessary content and interactive modules into native mobile applications for use on Android and iOS smartphones and tablets.

    First the technician can choose either English or Mandarin instructions. The Industrial Augmented Reality experience starts when the technician points the camera of the mobile device on which the application is running at the inverter. The target is automatically recognized, and a list of procedures available for the model appears on the screen. The procedures may be assigned by the maintenance manager to one or more technicians, or they can be initiated entirely by the engineer in the field.

    Once the technician begins a procedure, a series of steps are shown, each accompanied by instructions that simplify the operation to be performed and by Augmented Reality elements which, depending on the need, may be highlights of the intervention points or procedural animations. HyperIndustry platform by Inglobe Technologies allows the developer to associate additional contextual information, such as technical documents, photos and videos previously prepared by the technical documentation team, with each step.

    Field technicians independently perform technical procedures by executing all required steps. The procedures may be either followed linearly or accessed as required, as a result of the definition of branches and paths depending on the use case or the context. Checklists and steps in the application help the operator to perform inspections and audits. The platform records the technician’s performance, then sends all of the performance metrics and analytics to managers so they can assess the processes.

    The technologies involved in the project

    HyperIndustry is a modular platform based on a content management system that allows corporate asset management in the context of an Augmented Reality workflow for Industry 4.0. The project consists of 3D models, tracking data of the equipment, images, videos, animations, documents, and other information considered valuable for the design of procedures, and management of users and assignments.

    The platform includes a series of profiles to be associated with business roles including technical manager, who can create and assign tasks with a user-friendly interface and the field technician who receives the requests on his device. An analytics control panel is included in order to analyze data and customizable indicators (KPIs).

    The platform’s recognition of 3D objects uses an advanced 3D tracking technology designed to deliver AR experiences efficiently and reliably on mobile and wearable devices.

    The Benefits for Huawei

    Existing studies show that the use of Augmented Reality when performing complex procedures in the field can improve performance of technicians in the workplace. Augmented Reality–assisted instructions help the professional access all the relevant information where and when needed. By reducing the need for training and avoiding errors during the performance of tasks, AR can significantly reduce costs, compared to traditional methods of delivering documentation.

    Compared with the traditional paper-based or digital instructions, one of the most obvious benefits related to the installation and maintenance instructions is the technician’s immediate understanding of each step in the operation. The use of Industrial Augmented Reality has, in fact, allowed Huawei to make understanding procedures faster and less ambiguous, reducing the cognitive load for the operator. Consequently, the average execution time of the procedures could decrease.

    This ease of access to information is a key factor that not only speeds up the execution of procedures by new technicians, but can also help the experienced staff in solving occasional and complex problems, through a true “perceptual intelligence system”.

    Rhonda Truitt, Director of US R&D Technical Communication Innovation & Best Practices at Huawei, referring to the project declared: “The results we achieved on this project through Inglobe’s HyperIndustry were nothing short of amazing. Object recognition on outdoor equipment was something other vendors told us could not be done. Our customers have responded overwhelmingly positive about this experience. I am confident that we will see a sharp decline in installation errors due to this AR experience for post installation checks. Inglobe has really impressed me.”

    Plans for the future

    Huawei plans to continue working on Augmented Reality workflows that integrate Technical Documentation, Product Lines and support for Customers and Technicians in the field.

    >>> Download Case Study PDF <<<

  • Smart manufacturing using AR in the era of Industry 4.0

    Smart manufacturing using AR in the era of Industry 4.0

    The debate around industry 4.0 and smart manufacturing is involving an increasing number of execs worldwide, but that doesn?t mean they are all aware of the potential benefits of this trend for their companies. Same goes for the challenges to be tackled before a company can speak the industry 4.0 language.

    Augmented reality is one of the cutting edge technologies involved in the industry 4.0 trend when talking about smart manufacturing, it is a technology which was seen just as a fancy toy until a few years back, but which has now reached the right level of maturity to be employed in a productive environment.

    The truth is many actors in the industry field still feel like something big is going to happen on their shop floor in the next future, but they don?t know exactly when and what.

    As for the when, we are much more advanced in the adoption of industry 4.0 practices than the non-experts may understand. There are so many investments and pilot projects going on out there which are speeding up the process of refining the technology and getting companies ready to improve their processes. In fact, sectors such as gaming are not lagging behind, with initiatives like ξενα καζινο στην ελλαδα paving the way for innovative solutions and new market opportunities, driving competition and technological adoption. So the right time is right now, at least for those who want to be the leaders.

    As for the what, the range of potential applications is very wide, although some trends have emerged where augmented reality has proven to increase process and people performances as well as being effective at driving down costs in so many departments.

    Critical issues in Industry 4.0 environments

    Processes in the productive environment exhibit a number of critical issues that make operations less efficient, as well as more risky for technicians working in the field.
    These are the areas of focus according to our experience:

    1. Human error: even the most experienced workers may suffer from an information overload resulting from excessive amounts of procedures to remember and difficulty in identifying the exact intervention points
    2. Inefficiencies: according to some empirical studies traditional assembly and maintenance operations require longer execution times compared to the same operations carried on with the assistance of augmented reality. Use of wrong tools, inadequate training received by technicians and poor to none access to operations? analytics are some of the most recurring inefficiencies inside factories
    3. Cost: all of the above translates into higher workforce costs due to longer operations, recurring errors and damage to components due to incorrect procedures execution

    Empirical studies and the evidence of performance improvement

    There is a number of empirical studies conducted on the field in order to research the effectiveness of AR applied to industrial operations.
    This set of studies compares the performance of two groups of workers carrying on the same assembly or maintenance operations, one group operates with the aid of AR instructions, the other group with the support of traditional printed instructions.

    Among these studies, some of the most notable are ?Augmented Reality Efficiency in Manufacturing Industry: A Case Study? by J. Saaski, T. Salonen, M. Liinasuo, J. Pakkanen, M. Vanhatalo, A. Riitahuhta and ?Evaluating the Benefits of Augmented Reality for Task Localization in Maintenance of an Armored Personnel Carrier Turret? by S. J. Henderson, S. Feiner.

    What researchers have highlighted is a performance improvement up to 50%, which means AR enables workers to perform a given task faster and with a lower possibility of error.
    All of this evidence translates into economical benefits as well, since reduced execution times means a lower cost of labor.

    Potential usage scenarios for Industry 4.0

    The range of possible use cases is really wide and involves nearly all kind of operations that can be executed on the shop floor, from core manufacturing activities such as production to support processes such as maintenance, training and so on.
    The following is a list of potential usage scenarios according to our experience.

    1. Operations: any kind of operation which requires some step by step procedure can benefit from the introduction of augmented reality. Installation, assembly, machinery tool change are just some of the processes where AR can make a difference and make manufacturing really smart
    2. Maintenance and Remote Assistance: industrial companies know how much time-consuming the maintenance tasks can be. Preventive, corrective and in some cases predictive maintenance requires companies to allocate many human and financial resources to guarantee the operations smoothness and minimize machinery faults. In this context AR is extremely effective at reducing execution times, minimizing human errors and sending the relevant performance analytics to maintenance managers.
    3. Training: especially for those companies where training is a critical process involving many field technicians AR guided training mode can be very effective both for experienced people and new technicians at the beginning of the learning curve
    4. Quality control: AR support in quality control processes allows to check wether the items produced respect or not the best manufacturing standards.
    5. Safety management: AR makes available the tools to manage risk and safety of operators and equipment working in the facilities
    6. Design and visualization: in this scenario of usage augmented reality comes into play providing tools that improve design, prototyping and visualization in the design phase
    7. Logistics: tools that can improve efficiency of warehouse management operations and logistics supporting operators during indoor navigation and picking operations.
    Augmented Reality SDK Object Recognition car engine

    HyperIndustry: one platform to manage it all

    Inglobe Technologies? solution is a mobile and wearable platform designed to support smart manufacturing activities; it is equipped with advanced Augmented Reality features that can be integrated into technical processes in different industries.
    It enables a more effective communication between field workers and business infrastructure in order to provide contextual and smart information about installation and maintenance.

    The platform allows key people inside companies to create and manage augmented reality experiences including object tracking, tasks creation and assignment, data analytics management.

    Our Mixed Reality platform can be integrated into IoT solutions and Advanced Visualization / Interaction, includes different customizable modules and supports mobile devices, smart glasses and standalone systems.

    Visit HyperIndustry Product Page now!

  • Smart Maintenance: An Augmented Reality Platform for Training and Field Operations in the Manufacturing Industry

    Smart Maintenance: An Augmented Reality Platform for Training and Field Operations in the Manufacturing Industry

    Inglobe Technologies announced today the release of a new whitepaper titled SMART MAINTENANCE : An Augmented Reality Platform for Training and Field Operations in the Manufacturing Industry.

    The white paper discusses a selection of Inglobe Technologies Augmented Reality (AR) solutions to enhance both training and operations in different industrial maintenance scenarios.

    AR applications provide a technology that has the potential to support and speed up training, while at the same time increasing performance and effectiveness levels. Some statistics suggest performance improvements up to 30% with involved employees reporting higher levels of engagement. Applications of AR that support technicians in the field have the potential of reducing costs up to 25% throughout quicker maintenance or component substitution, identification and setup of new connections, solution of faults and misconfigurations, with less burden on backend personnel and system resources. Additionally, thanks to the information that operators collect on the field, the AR technology contributes to an improvement of the quality of enterprise data.

    Development of AR applications in an industrial setting is a complex task, made even more challenging by the need to leverage the full power of native platforms (iOS, Android, Windows). This is certainly the case of modern, cutting edge AR mobile applications. Inglobe Technologies simplifies this complex task by providing software components, technology, expertise and customizable solutions that help managing complexity with reduced time from requirement analysis to deployment.

    In order to present and educate on the software components needed to develop an effective AR solution for industrial maintenance, the document offers an overview of the challenges, enabling technologies and required solutions.

    The document also clarifies how, according to the authors, the adoption of an AR strategy (i.e. a strategy for the introduction of AR for industrial maintenance), is not a consequence of an improvised choice, but rather the result of a path that requires the definition of a?Roadmap?for the development of Enterprise Class AR solutions.

    The document addresses the challenge of making industrial maintenance more efficient under two main respects, i.e. the intelligent support of field force operations and training; section 1 introduces the dimensions from which the need for developing a Smart Maintenance solution derives; section 2 introduces the technologies that enable AR solutions for maintenance, including positioning technologies, pattern recognition, tracking and artificial vision as they allow to create effective and enhanced industrial solutions; section 3 offers an overview on the architecture of the proposed solution; a generic use case which is relevant in this context is discussed in section 4; section 5 discusses an approach to estimate the ROI (return on investment) by clarifying the reference parameters for evaluating quantitatively the benefits that the adoption of an AR strategy for maintenance provides; finally, section 6 offers an approach and Roadmap for the design and implementation of an enterprise class industrial Augmented Reality solution.

    The english version of the white paper can be downloaded from here: Smart Maintenance 041213_en