Augmented Reality Case Study in Heavy Manufacturing

1. DAQRI
C A S E S T U D Y O F A R I N
H E A V Y M A N U F A C T U R I N G
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Power & Gas Division
Generation of power from renewables and O&G
€19.5Bn orders in 2016; 37,000 employees
SGT-8000H gas turbine series - 425 MW
Training of 500 technicians is complex, time
consuming and costly
Investigate the value of AR for Training for one
specific assembly task in the full process, evaluate
whether further investment is justified
D M D I I / M C K I N S E Y C A S E S T U D Y

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THE
BUSINESS
GOALS
Improve scalability of training
Hands-free access to instructions/models
Simplify documentation overhead
Speed up learning time
Speed up task completion time
(1 day for novice level à 1 hour for
experts)
Better understanding = better confidence
Less need to re-check work and get second
opinions
Reduce variability between users
Reduce potential for error (linear process)
Refresher training for intermediate users
D M D I I / M C K I N S E Y C A S E S T U D Y

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DAQRI
TRAINING
SOLUTION
W E M A K E A N
I N D U S T R I A L A R H E L M E T

6. DAQRI SMART HELMET® has the
potential to revolutionize the future of
work.
DAQRI SMART
HELMET®
Certified hard-hat and eye protection
Hands-free, heads-up access to 3D work
instructions, models, expertise and help
Visual computing interface
D M D I I / M C K I N S E Y C A S E S T U D Y

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DAQRI
TRAINING
SOLUTION
TRAINING APP FOR DSH
Interactive 3D Models
Work Instructions
REMOTE EXPERT
2-way Video Connection to an Expert
Worker’s POV
HANDS-FREE DOCUMENTATION
Speech-to-Text Input
Automatic Logging
4 (OF 500) WORKERS STUDIED
2 Novices
1 Refresher
1 Expert
D M D I I / M C K I N S E Y C A S E S T U D Y

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CURRENT
WORK
PRACTISE
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Read technical drawings, memorize
assembly steps
Carry out assembly (non-linear) from
memory
Write down material numbers on paper
Enter material into report following task
D M D I I / M C K I N S E Y C A S E S T U D Y

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NEW WORK
PRACTISE
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3D instructions overlaid on work item
Worker follows linear assembly process
Voice-to-text & photo-capture to record
material numbers and steps taken
‘Document as you go’
D M D I I / M C K I N S E Y C A S E S T U D Y

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USER
FEEDBACK

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“With support like this, I would be able to do
any assembly”
“This kind of system is a good support
system for guys like me who don’t have any
information… I feel... very safe with the
system”
“Without the helmet, learning this assembly
would take me a day” (took 45mins)”
THE
NOVICES
D M D I I / M C K I N S E Y C A S E S T U D Y

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“It helped me see some things I didn’t
remember from when I originally wrote the
assembly procedures”
“It’s quite nice to see the work steps on my
right… I see I’ve got four tasks in total; I’m
on task three”
THE
REFRESHER
D M D I I / M C K I N S E Y C A S E S T U D Y

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“Humans are very visual, if I can interact
with the drawings in 3D like this, it makes
understanding them a lot easier, especially if
I have to deal with new components that I
have never built before”
THE
EXPERT
D M D I I / M C K I N S E Y C A S E S T U D Y

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OUTCOMES
EFFICIENCY
Linear, automated training rather than non-
linear in-person training
Hands-free operation saves time
Benefited all levels of user
ERROR REDUCTION
Prevented variability in assembly process
Streamlined data collection
Reduced effort for report generation
SPEED
Accelerated time to learn (1 day à 45min)
Hands-free access to instructions/models
D M D I I / M C K I N S E Y C A S E S T U D Y

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CONTENT CREATION
Manual import of 3D models and work
instructions from PLM
Working on automation
SCALE ACROSS USER BASE
4 of 500 workers using today
Expand use cases and integration
SYSTEM INTEGRATION
Integration with ERP system
SECURITY
Encrypted WiFi
PRACTICAL
CHALLENGE
S
D M D I I / M C K I N S E Y C A S E S T U D Y

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FURTHER
INITIATIVES
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TRAINING APP FOR DSH
AR Native work instructions
Interactive 3D models as standard
Industry-standard PLM
MIGRATE TRAINING TO AR
6 weeks classroom
7 weeks in-person coaching
Shorten to 1-2 weeks total
SCALE ACROSS USER BASE
4 of 500 workers using today
D M D I I / M C K I N S E Y C A S E S T U D Y