Why?

At TT PSC,<strong> we believe that manufacturing leaders should rely on reliable, real-time data to achieve the real goals of Industry 4.0 (r)Evolution. </strong>This data can build knowledge and awareness and identify actions requiring improvement.<br><br>In the Lesson Learned Explained series, we present examples of completed projects along with insights. <strong>We hope that this short material will help you avoid at least some of the pitfalls on the way to Digital Transformation.</strong>

Challenge: Becoming an innovation leader

A pharmaceutical company aimed to enhance its innovation by actively testing modern technologies. A key challenge was skillfully and effectively integrating technological innovations into the production area so that data could be collected and analyzed in real-time. The company wanted to show that it is in the „close peloton” of digitalization of production, thereby increasing its market competitiveness.

Solution: System integration and AR/VR implementation

To achieve this goal, the company, with the support of TT PSC experts, implemented a solution that integrated data collection from the manufacturing process. The key element was data visualization using augmented reality (AR)/virtual reality (VR) through Microsoft’s HoloLens glasses. Thanks to this, operators could see IIoT data in real-time, improving the efficiency and precision of their work. This solution was also aimed at increasing employee engagement and building a strong position as a market innovator through the use of cutting-edge tools.

Implementation challenges: Limited advantage of AR/VR and HoloLens over standard HMI

Despite the impressive graphical presentation of the AR/VR application on dedicated headsets, the solution did not bring the expected results. It turned out that AR/VR did not show a sufficient advantage over the standard HMI (Human-Machine Interface; touch panel/screen located on the machine) in everyday operations. As a result, operators were reluctant to wear the headsets while performing their duties, which resulted in low adoption of the technology.

Correction: Redefining business problems and adapting technology

In response to these challenges, the company reassessed its actual business needs and expected outcomes. The technology was then adapted to align with real operational requirements, enabling a more effective use of available tools. This process involved consultations with operators to better understand their needs and expectations. As a result, a more practical and user-friendly solution was developed, improving adoption and usability in everyday operations.

Result: Effective identification and solution of problems

Operators initially rejected the AR/VR solution because it did not offer substantial advantages over the existing HMI. However, after reevaluating the approach and tailoring the technology to real user needs, the company was able to develop a more effective tool. This experience highlighted the importance of adapting technology to meet the specific requirements of end users, ultimately leading to better utilization of available resources.

Conclusions

Based on the activities carried out, several key conclusions can be drawn:

  • Clearly defined business goals are key to evaluating results (Proof of Value instead of Proof of Concept).
  • A well-defined technical scope is crucial for managing budgets and timelines while ensuring a strong cost-to-value ratio.
  • Innovation and fascination with new technologies should not be the only motivations – getting stuck in the pilot phase is easy.
  • Even pilot projects should be designed with future scalability and broader implementation in mind.

Are you interested in digital transformation for your enterprise?

Check out other implementation examples below and the lessons learned from them.