What is Industry 4.0?

Industry 4.0 is the expression we use to refer to the fourth industrial revolution, a change in the way of organizing the productive means involved in the introduction of digital technologies in industry.

Industrial digitalization is a transformation towards the implementation of hyperconnected smart factories, where it is possible to access and modify, in real time, the behavior of the different elements that make up the system. In this fourth industrial revolution, technology is leveraged to enhance the efficiency, productivity, quality, and safety of industrial processes.

Industry 4.0 through Virtual Reality and Augmented Reality

Virtual Reality (VR) and Augmented Reality (AR) are two essential technologies for the transition to Industry 4.0, as they enable industrial companies to embark on this path towards digitalization.

Both technologies use virtual environments (Virtual Reality) or integrate virtual elements into reality (Augmented Reality) that provide knowledge and useful information for process optimization. Specifically, there are four areas of application for these technologies, which we will enumerate next.

Applications of Virtual Reality and Augmented Reality in Industry 4.0

• Design optimization
• Plant maintenance and control
• Operations instruction and personnel training
• Incident assistance and resolution

Advantages of using Virtual Reality and Augmented Reality in Industry 4.0

The implementation of Industry 4.0 through virtual reality and augmented reality brings several benefits to industrial companies, highlighting the following:

• Process improvement
• Reduction of waiting times
• Increased safety
• Cost savings

Examples in Industry 4.0 with Virtual Reality and Augmented Reality

We now proceed to analyze each of the Industry 4.0 solutions that incorporate Virtual Reality and Augmented Reality.

Optimization of designs with Virtual Reality and Augmented Reality

INDUSTRIAL PROTOTYPING WITH VIRTUAL REALITY

There are industrial sectors where prototyping products involves high investment costs; it is necessary to physically create the products so that their characteristics can be appreciated and their design analyzed in detail. An example of an industry that requires these high-cost processes is the automotive industry. Until now, it was necessary to build, albeit with lower quality, the model that would later be marketed to analyze its real-world use.

And we say until now because Virtual Reality is the perfect tool to reduce costs associated with prototyping tasks. This technology allows creating a realistic simulation of the future product where all its characteristics can be visualized as if we had it physically in front of our eyes. This virtual creation also allows testing different finishing options without investment in prototyping.

BMW has been one of the first brands to use virtual reality to visualize, among other aspects, new interior designs of vehicles and other physical characteristics of their cars. These simulations are used to check aspects such as interior visibility of the car or whether the dashboard and controls are adequately visible from the driver’s position. This technology has allowed the German company to make decisions without resorting to the expensive simulation tunnels previously used for prototyping.

ASSEMBLY AND DESIGN OF FACILITIES WITH AUGMENTED REALITY

Augmented Reality, also known in this case as Mixed Reality, is useful for the assembly and design of facilities. The additional information that appears to technicians on these hands-free devices is essential to determine if the future project fits the real dimensions of the factory where it will be installed.

In this regard, we have pioneered work with Dicoma Pack, a leading supplier of bottling lines for Spanish wineries, in the development of augmented reality industrial applications that enhance tasks performed by companies dedicated to installing industrial machinery.

Specifically, we have designed an application for Microsoft HoloLens, Microsoft’s Mixed Reality goggles, which transform this device into an essential tool for designing and adapting facilities prior to assembly. Through this software, the device projects an augmented reality life-sized image of the machine intended for installation, allowing installation technicians to verify that the future installation fits the space and technical specifications of the client’s factory.

Maintenance and plant control with Augmented Reality

Another use of augmented reality focuses on the maintenance and repair of machinery. Typically, when a breakdown occurs, the operator does not have the instruction manuals for the specific machine at hand to proceed with the repair. They must search for them or consult a professional familiar with the machinery’s operation, resulting in lost time and production stoppage at the plant.

Augmented reality addresses these issues. When a breakdown occurs, the operator puts on augmented reality glasses and, through them, follows detailed steps from virtual instruction manuals projected onto the lens to resolve the issue. The glasses recognize different parts of the machine and visually guide the operator where to act to fix the problem.

or this field, glasses like Epson’s Moverio are used. With the company Dicoma Pack, mentioned earlier, we developed a project of this nature. Other international companies such as Caterpillar or Bosch have also used this technology, although they employ tablets for repair assistance with a virtual assistant.

Similarly, augmented reality technology can also assist in facility management. Plant managers can access real-time data from each production process through a tablet or smart glasses. Approaching each machine, the device would recognize it solely based on its image and project information on efficiency and productivity. These essential data points enable technicians to make decisions aimed at enhancing the overall operation of the plant.

Training for operations and operator training with Virtual Reality

The realm of training specialized technicians in the handling of industrial machinery is another application of virtual reality technology. Just as we can create environments to visualize machines operating realistically, we can enable users to interact with them to troubleshoot issues or incidents.

Simply with virtual reality glasses, it is possible to place an operator in a virtual environment where they can visualize a machine that has halted production, allowing them to check its operation and resolve the issue as if they were in a real factory environment.

Thus, Virtual Reality becomes closely aligned with training, offering industrial companies a much more efficient and cost-effective tool for training their workers. This eliminates the cost of a technician needing to train each worker individually, optimizes time, and avoids the need to halt production for training or allowing access to machines for practice.

In this regard, its application for training in risky situations is even more suitable. At Innoarea, we have developed several projects of this nature. We highlight our project for Femeval, a virtual simulation that demonstrates to workers the risks of working without proper safety measures. In addition to the cost savings mentioned earlier, this also prevents unnecessary risks to workers.

Assistance and incident resolution

Augmented Reality teleassistance applications represent a further step in the maintenance and repair tasks of machinery; in this case, factory operators are guided through the incident resolution process by expert technicians.

The factory operator connects live with the machinery manufacturer’s technical support. Through the camera integrated into the operator’s glasses, technicians can see exactly what the operator sees in real-time. This real-time vision is crucial for incident resolution, as it allows technicians to guide the operator accurately through each step.

This solution directly optimizes production times by avoiding long stops until the arrival of technical support. Moreover, its use results in cost savings for industrial machinery suppliers, as they do not incur travel expenses or the work hours of technical service professionals.

At Innoarea, we are actively developing such live communication solutions with experts, as implemented in various companies. You can view an example of teleassistance in the following video:

The importance of Virtual Reality and Augmented Reality for Industry 4.0

As we have seen, the application of these Virtual Reality and Augmented Reality solutions for industrial companies represents a significant step towards implementing Industry 4.0 in factories. Using technology to reduce downtime for breakdowns or to resolve incidents by connecting live with technical support are real implementations of connected industry in manufacturing plants. It’s another step towards industrial digitalization achieved with technology that many would consider more related to the realm of video games, but as we have seen, it is fully industrial.

We invite you to contact our team if you have any questions or if you are interested in implementing any of the solutions we have just discussed in your company.