How Today's Virtual Reality Technology is Improving Business Collaboration across the Manufacturing Sector

By: John Tomblin, Senior Solutions Architect
Data Titan, a division of Sofvue, LLC
Printed with permission of Data Titan, Sofvue LLC, and the author

Enhancing Manufacturing Processes with Virtual Reality: A Modern Solution to Complex Challenges

Manufacturing is an intricate and multifaceted process, often involving hundreds or even thousands of steps. A single minor issue on the assembly line can lead to a complete shutdown—not only from human errors but also due to failures in support software, hardware, or even the physical infrastructure.

For example, one manufacturing client faced a significant interruption caused by an unforeseen partial collapse of a second-floor assembly area when one area of the second floor was used to store hundreds of pallets of parts, but the weight was unsustainable. Fortunately, no one was hurt, but parts of the assembly floor on both levels became inoperative for days, and although the assembly lines were operational again within three days, the peripheral damage took months to resolve. This incident underscores the critical need for robust systems to minimize downtime and maintain operational efficiency, and by partnering with a software development company like Data Titan, manufacturers can develop custom apps that monitor infrastructure, predict potential issues, and streamline responses to disruptions. These solutions help mitigate risks, ensure continuity, and provide real-time insights to manage complexities effectively.

From prototype development to full-scale production, every stage in manufacturing comes with stringent requirements. Deviations from these standards can lead to mistakes, compromising not only the quality of the product but also the safety of workers, with potential risks of injuries or fatalities.

However, advancements in technology, particularly virtual reality (VR), are revolutionizing how manufacturing companies train employees, enhance safety, and maintain quality control throughout the production process.  A few examples include:

1. Simulating Emergency Scenarios

Using VR designed scenarios, workers can practice responding to emergencies, such as equipment malfunctions, chemical spills, or fire outbreaks. For instance, VR could simulate a conveyor belt jam, teaching employees how to safely shut down the system without causing additional potential harm to other employees.

2. Identifying Safety Hazards

Through VR, workers can walk through a virtual version of the production line and identify potential hazards, such as misplaced tools, improper wiring, or blocked emergency exits.

3. Reinforcing Safety Protocols

VR can incorporate company-specific safety protocols, ensuring employees are well-versed in procedures such as wearing personal protective equipment (PPE), adhering to lockout/tagout protocols, and maintaining safe distances from hazardous machinery.

While VR has existed since the 1960s, its adoption in manufacturing has only become practical and cost-effective within the past decade. Today, it plays a transformative role in improving efficiency and collaboration within the industry.

According to Fortune Business Insights, the global VR market in the manufacturing sector was valued at $924.7 million in 2018 and is projected to grow to $1.4 billion by 2026, with a compound annual growth rate (CAGR) of 39.2% from 2019 to 2026. This rapid growth underscores the potential of VR to address critical challenges in manufacturing.

With these figures in mind, let’s explore how virtual reality is reshaping collaboration, safety, and efficiency across the manufacturing landscape.

Step#1. VR as a Training Tool

Virtual reality (VR) has revolutionized employee training by offering a more effective alternative to traditional methods. Through immersive simulations, VR allows employees to experience and practice scenarios that would be too risky, costly, or impractical to replicate in real life.

In manufacturing, VR proves invaluable by enabling employees to develop new skills without the risk of mistakes that could damage expensive equipment or products. It also helps ensure adherence to Occupational Safety and Health Administration (OSHA) safety standards and quality assurance (QA) protocols. Furthermore, VR training reduces waste caused by errors in manufacturing processes, making it both a cost-efficient and environmentally friendly solution.

Step#2. VR for Remote Collaboration

Contrary to the assumption that manufacturing relies exclusively on in-person interactions, VR makes remote collaboration not only possible but highly effective. For example, imagine a floor manager on a business trip in New York collaborating with an assembly manager at a plant in Mobile, Alabama. With VR systems powered by cloud technology, both managers can assess and resolve process issues in real time from anywhere in the world.

VR facilitates seamless teamwork across geographically dispersed teams (as long as time zones align). It’s also an excellent tool for onboarding new employees remotely. They can learn job-specific processes and develop skills from home, reducing training costs and enabling them to perform more effectively once on-site.

Step#3. Preview Projects Before Completion

VR enables manufacturers to create and interact with 3D simulations of projects, offering engineers, designers, and clients the ability to view, modify, and optimize designs before production begins. This real-time interactivity helps identify potential issues early, minimizing costly revisions during production.

For instance, automotive teams can use VR to present a fully visualized car design to engineering teams, allowing them to make adjustments before physical manufacturing begins. This significantly improves development timelines, accelerates go-to-market schedules, and enhances ROI.

Additionally, VR improves communication with third-party vendors by providing a clear visual representation of ongoing projects. Changes on the manufacturing floor can be made remotely using VR tools, keeping production on schedule while ensuring access to all necessary information. This reduces downtime and streamline operations.

Step#4. Real-Time Monitoring and Analytics

VR also serves as a powerful tool for real-time monitoring of manufacturing processes. This capability is especially valuable when managing large-scale production and monitoring assembly lines for efficiency and accuracy.

By using VR, manufacturers can plan production workflows and optimize material usage before a project begins, reducing costs and waste. Real-time analytics provide timely and accurate data for better decision-making in areas such as production planning, inventory management, and equipment performance.

Importance of Mobile Apps for Virtual Reality

Virtual reality (VR) has revolutionized employee training by providing immersive, firsthand simulations that surpass traditional training methods. By selecting a custom mobile app development company like Data Titan, businesses can develop tailored VR training solutions to meet their unique needs. These apps simulate real-world scenarios that might otherwise be too risky, expensive, or logistically challenging to replicate in a live environment.

Real Examples of VR Use Today

It is not enough to understand what VR is, you have to understand its real-world applications.  Here are three companies who have used VR as part of their business model, along with an explanation of how they are using VR.

#1. zSpace

Founded in 2007 and based in San Jose, California, zSpace developed VR and augmented reality (AR) solutions for educational purposes. Their technology allows students to interact with 3D models across subjects like science, technology, engineering, art, and mathematics (STEAM). By 2015, zSpace had released an updated version of its desktop all-in-one system, zSpace for Education, enabling users to manipulate virtual 3D objects, such as building circuitry and experimenting with gravity.  Wikipedia

#2. Dreamscape Immersive

Established in 2016 and headquartered in Culver City, California, Dreamscape Immersive created story-based, full-roam VR experiences. Their installations allows multiple users to explore virtual 3D environments simultaneously. In February 2018, they launched their first VR installation, "Alien Zoo," at the Westfield Century City Mall in Los Angeles, providing immersive entertainment experiences. Wikipedia

#3. Within

Originally named Vrse and founded in 2014 by Chris Milk and Aaron Koblin, Within was based in Los Angeles, California. The company produced and distributed VR and AR content. In April 2020, they released "Supernatural," a home fitness service for VR that combined real-life trainers with rhythm-mapped exercises set in various outdoor locations, offering users immersive workout experiences.  Wikipedia

Conclusion

VR can create a collaborative environment and 360-degree experiences for your company’s workforce, both on-site and remotely. With VR, you can build a virtual environment where multiple people can work together in the same space, especially for training, safety and or design.  

Data Titan has been developing custom web-based, mobile and MVP solutions for companies since 2004, from Los Angeles to New York City. To date, we have designed, developed, and prototyped hundreds of application and mobile systems, for over three-hundred companies, and we are correctly poised to provide those same services to you and your small business. To learn more, contact us at 623-845-2747.

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Citations:

Fortune Business Insights

https://www.fortunebusinessinsights.com/industry-reports/virtual-reality-vr-in-manufacturing-industry-101714

Wikipedia

https://en.wikipedia.org/wiki/ZSpace_%28company%29?

Wikipedia

https://en.wikipedia.org/wiki/Dreamscape_Immersive?

Wikipedia

https://en.wikipedia.org/wiki/Within_%28company%29?