New Augmented Reality Technology Accelerates Efficiency, Improves Quality in Manufacturing

Video games like Pokémon GO use augmented reality (AR) to enable Pokémon to appear in and around the real-world environment in front of you. Ford is now using the same type of technology in manufacturing to enhance on-the-job training by immersing operators into the real-world machining environment, improving efficiency, enhancing quality, and eliminating waste.

Dearborn Engine Plant is one of the first manufacturing facilities to employ the new AR technology, which utilizes a Microsoft HoloLens headset.

“Users that have never performed a complex process are guided through it with step-by-step instructions using the headset, and they can execute a task with a level of accuracy and precision that only a small number of experts could achieve previously,” said Tim Mwenje, team manager, Dearborn Engine Plant. “In addition to enhancing new-hire training, accelerated learning through AR provides new opportunities for existing employees to broaden their skillset and elevate their careers in a low-pressure environment, giving them the confidence to take on new, more complex responsibilities.”

Mwenje said the AR tool leads trainees through every step in the operator instruction sheet, giving new users a better grasp of the fundamentals.

“It gives them the confidence to step into the job and do it effectively on day one, enhancing the quality of our processes,” he said. “Plus, the AR tool can guide operators, even those with no prior experience or expertise, through complicated assemblies and inspections with 100% accuracy.”  

Since trainers no longer have to coach or monitor operators throughout on-the-job training, they are getting the time back to resume their regular daily activities, eliminating waste in the system.

“This is especially true in machining where precision is critical and a trainer was required to guide a trainee through every step,” said Mwenje.

In addition, the training process is faster using the AR tool, providing up to two months of training experience in approximately two weeks.