Although VR and AR are years away from mainstream adoption in manufacturing, it seems like they have a prosperous future. Leroy Spence looks at how AR and VR are changing the world of manufacturing

The Oculus Rift, Microsoft HoloLens and even Google Cardboard are a far stretch from the first virtual reality (VR) headset, created in 1968 by computer scientist, Ivan Sutherland.

The concoction was called the sword of Damocles and, because of its formidable size and weight, had to be anchored to the ceiling so it didn’t crush the user.

Almost 50 years later, we are only now seeing VR and augmented reality (AR) being used in manufacturing environments.

Like any disruptive technology with roots in the consumer market, industry viewed VR with a certain level of scepticism to begin with. Many companies questioned the practical applications of the concept, labelling it another gimmick that would not stand up to the rugged manufacturing environment.

However, like Ethernet, touch screen and mobile devices proved before it, VR has real-world manufacturing potential.

New concepts and technologies are prone to hype. In 2015, Gartner's Hype Cycle saw VR emerging from the Trough of Disillusionment into the Slope of Enlightenment – this means VR started being used for real-world useful applications. In 2016, we are betting the technology will continue its ascent as more manufacturers start to take advantage of its benefits.

Indeed, a PWC survey at the beginning of 2016 found that more than a third of the US manufacturers surveyed, already used VR technology or planned to do so in the next three years.

Virtual design

The automotive market tends to be an early adopter of disruptive technologies — including automation, robotics and now VR.

The US automotive manufacturer Ford built its own immersion lab where designers, engineers and other employees can don an Oculus Rift headset and walk around exploring the exterior and interior of its cars.

Ford uses VR to test its designs and assess how individual elements of a vehicle look, without having to build a physical car. The VR links directly with the company's computer aided design (CAD) software, so engineers can make changes and visualise results quickly and easily.

Virtual training

Another area in which manufacturers are seeing VR shine, is training. The British engineering firm, BAE Systems recently revealed that it creates virtual representations of projects, such as ships, for engineers to practice on.

BAE's virtualisation suites allow engineers to examine the virtual elements of a system, so they can analyse, design and plot where they need to make changes in the physical world. VR provides a level of test redundancy by giving engineers the chance to try out changes before they make any final alterations.

VR training programmes can simulate realistic and hazardous situations on the manufacturing floor, including chemical spills, dangerous machinery and loud environments, without putting operators at risk. Should the unavoidable happen, employees have relatable experience and are more likely to react appropriately in an emergency.

Furthermore, VR is an effective way of teaching machine operators or maintenance technicians about a new piece of equipment on the factory floor. Visualising the inner components of devices allows companies to make detailed maintenance plans. This process is incredibly useful for identifying obsolete components or predicting which parts the original equipment manufacturer will cease to support in the near future.

This allows plant managers to create an effective obsolescence management plan, which could involve stocking up on spare parts or opting for a redesign.

Virtual factory

Perhaps one of the biggest indicators of the potential of AR and VR for industry has come from a shift in recruitment at major engineering companies. Recently, firms have been very open about actively recruiting graduates with game design degrees.

Astute with VR, Android and mobile technology, this next generation of engineering recruits are helping make Industry 4.0 and Internet of Things (IoT) applications a reality.

Although VR and AR are years away from mainstream adoption in manufacturing, the technology is being put to good use by a minority of progressive companies, looking for a competitive edge. It seems VR and AR both have a prosperous future in the manufacturing industry; those willing to invest in the virtual world will be rewarded in the physical.

Leroy Spence, head of sales development at industrial spares supplier EU Automation.