Augmented Reality in the plastics industry: individualized instructions for the entire product life cycle

AdaptAR generates instructions automatically and facilitates work on machines

Exclusively for K-MAG

Image: Business woman with smart glasses; Copyright: westend61

25.08.2022

Individualization is the trend. In the plastics industry, too, more and more individualized machines are coming onto the market. Of course, these machines also require individualized manuals with instructions tailored specifically to them. However, this is not yet a reality today. The AdaptAR project wants to change that – with the help of Augmented Reality and an app.

You're operating a machine, suddenly a problem arises, and you naturally look directly in the manual – but you just can't find the right answer to your question. Does that sound familiar? This could be because the manual is not tailored to your specific product type, or because your manual is only available in paper form, making it much more difficult to look up specific information.

AdaptAR solves contradiction between need and reality

Today, user manuals are still often published in paper form. For the most part, they are created manually – at the beginning of the product lifecycle. Subsequent changes to the product can no longer be taken into account. As a result, the information is not geared to the actual needs of users.

This is precisely where the AdaptAR project comes in. Karl Lossie from the Fraunhofer Institute for Production Technology IPT – coordinator of the joint project – explains the thinking behind it:

In the AdaptAR project, an app and several software components are being developed. With their help, individualized instructions are to be generated on the one hand, and on the other hand, these can be used in practice.

The 5 core components of the project are:

1. Smart Service

Algorithms are to be developed with which concrete instructions with step-by-step instructions can be automatically generated from a database for the respective concrete use case, for example the maintenance of a machine.

2. Digital Twin

To this end, a database is to be set up in the project and a Digital Twin developed for each machine or system, which brings together all the associated order, product, process and resource data in a local database. In this way, all the information needed to create a manual is available in a standardized form. The Digital Twin is enriched with further data from connected IT systems during use.

3. Interface between human and Digital Twin in Augmented Reality (AR)

Using digital devices such as tablets or smart glasses, machine operators are to be guided to an individual solution to the problem directly at the point of use.

4. Smart Service platform

The platform is to enable the transformation of information from all relevant software systems for the generation of instructions for action.

5. Legally compliant design

A legally compliant design should ensure the transfer of all project results.

Graphic: concept for the provision of adaptive and context-specific instructions for action throughout the product life cycle; Copyright: Fraunhofer IPT.

Concept for the provision of adaptive and context-specific instructions throughout the entire product life cycle. Copyright: Fraunhofer IPT

Maintenance, documentation & Co. – AdaptAR in practice

To achieve these goals, the Fraunhofer IPT is supported by a total of 12 project partners - including DEGUMA-SCHÜTZ GmbH. This company manufactures rolling mills for rubber processing.

User companies such as DEGUMA-SCHÜTZ can use the planned software in various use cases throughout the entire product life cycle.

Image: Man with smart glasses at a machine; Copyright: Fraunhofer IPT

In addition to maintenance, the software can also support the assembly of the company's own products, commissioning and operation at customers' sites, and finally even the reconditioning of plants. Companies thus not only save costs for skilled personnel and travel, but also time.

DEGUMA-SCHÜTZ GmbH also aims to improve its documentation in the project. This plays a particularly important role for the manufacturer in another of its fields of activity, the sale of used machinery.

Thus, with the help of the results from the project, a high quality of documentation can be achieved for the buyers of the used machines from DEGUMA-SCHÜTZ. Less paper also means less waste and thus greater environmental awareness.

Overcoming barriers thanks to AR

In addition, fewer downtimes and accidents occur due to improper operation of the equipment – on the one hand due to the availability of instructions that are precisely tailored to the product type, and on the other hand due to user-friendliness and specificity.

Image: Man with tablet with AR function in a production hall; Copyright: Fraunhofer IPT

For example, certain steps in the app may have an AR representation, while other steps may not - depending on the user's preference or experience. As soon as a process is completed, any changed data is also stored in the Digital Twin. Based on the history, it is always possible to see exactly what people who previously worked on the system did or changed.

AdaptAR also aims to overcome any language barriers thanks to its translation function. This should eliminate another source of errors when operating plants.

Martin Schulz also told us what potential he sees in AR for the plastics industry:

The AdaptAR project has been running since June 2020. At the current time, all requirements have been defined and individual software components planned. The next step is to convert these components into demonstrators.

The first presentable project results are expected at the end of 2022. Users should then be able to test the instructions in different use cases. The project will run until May 2023.

Augmented Reality can significantly simplify service processes in the plastics industry, for example plant maintenance, and thus make them more efficient and user-friendly. This is demonstrated by the AdaptAR project.