Assisted Reality (AR) in Manufacturing

Enable Line Workers with Secure Hands-Free Collaboration

Digital workspaces are transforming how organizations think about operational efficiency and productivity. But when it comes to manufacturing, digital transformations must also promote and support safety around machinery or in dangerous working environments. That’s why augmented reality or assisted reality in manufacturing has been slow to take hold — until now.

RealWear devices with assisted reality (AR) technology are leading manufacturing’s digital transformation with hands-free, Android-based smart glasses, designed specifically with safety in mind.

For Questions about Manufacturing Solutions

Hands-Free Solutions for Smart Factories

Smart factories focus on accelerating the assembly of products from supplier to shipping, reducing inefficiencies and ramping up production to meet growing global demand. Digital transformation through IoT, AI and connected workers will enable your workforce to work safely and effectively right next to collaborative robots to deliver tangible return-on-investment.

But this doesn’t change the inherent dangers of working around machinery. A digitally transformed manufacturing factory floor is still bustling with loud and distracting activity that can cause serious injuries. Workers need to be able to navigate these environments while doing their job safely.

But efficiency doesn’t have to come at the cost of safety — or vice-versa. RealWear devices empower workers by helping them get the information they need at the right time and in the right context.

With the power of a wireless Android tablet in the form of smart glasses, workers can access and view equipment manuals, multimedia files, complete documents and collaborate with experts in real time with video calls. And because RealWear smart glasses are entirely hands-free, manufacturing workers can continue to work with their hands and view information without taking their attention away from their environment.

Key Benefits of Hands-Free Controls

RealWear assisted reality (AR) headsets are voice-activated to:

  • Help workers focus on their immediate surrounding
  • Enable faster access to and reference of resource materials
  • Allow the use of both hands
  • Work even when wearing heavy-duty protective gloves
  • Reduce risk of dropping other tools and equipment

Digital Transformation in Manufacturing with AR

SLA Fulfilment


Low situational awareness results in slow response. Technicians have difficulty meeting aftermarket SLA’s with a geographically distributed customer base, which triggers costly penalties.


Turn the customer into your field diagnostic team by calling customer support with video instead of voice. Technicians improve efficiency and accuracy by using the voice-activated HMT-1 with remote mentor solutions to: connect hands free with Product Quality Engineers (PQEs), capture images and videos, playback training videos, refer to manuals, and more.



When production stops due to machine failure, on-site technicians need assistance immediately to resume production. However, the expert for this machine may be located in a different city, state, or country.


Through peer-to-peer video collaboration on the HMT-1, experts can provide assistance by telestrating remotely to pin-point the exact issue – even in high-noise environments. Hands-free communication permits technicians the use of tools to operate machines.

Secure Docs


Workers do not have the latest knowledge for manufacturing operations, including machine installation, inspection, and maintenance procedures. Paper copies are kept in binders adjacent to the manufacturing lines for reference by operators, but these are cumbersome and pose a security risk.


Document navigator and single sign-on (SSO) allows documents to be securely synced to HMT devices. Operators simply scan a QR code on a machine and are brought directly to the correct document to address their issue. Files are then remotely wiped when security credentials are revoked.

5 Benefits of RealWear Assisted Reality (AR) in Manufacturing

Supports Safety Requirements

RealWear headsets are designed with safety in mind — in all industrial environments. They’re ruggedly durable and compatible with PPE including hardhats, eyewear, masks and even hazmat suits. The micro-displays are slim to maintain field of vision but are also adjustable to be moved out of the wearer’s view.

Improves Information Access

AR in manufacturing helps workers access the information they need safely and efficiently to improve the installation, monitor, maintenance and repair processes. While it’s possible to get the same access on other devices, laptops are cumbersome, tablets require two hands and smartphones can be easily dropped.

Assisted reality technology allows digital content to be displayed in the worker’s line of sight without inhibiting their line of sight — or taking their hands or attention off the task in front of them.

Increases Accessibility to Experts and Mentors

RealWear headsets’ high-resolution camera, wireless connectivity, noise-canceling microphones, and integrated audio enable manufacturing workers to remotely collaborate with offsite experts or mentors in real time. With seamless out-of-the-box integrations with collaboration applications (e.g. Microsoft Teams, Zoom, Librestream), the remote mentor can visually present information on the headsets’ micro-display.

Boosts Productivity and Efficiency

Having instant access to resources or information allows workers to be more knowledgeable about their job. Workers are able to access relevant information at the point of need and in the right context.

Reduces Operational Costs

RealWear headsets enable offsite supervisors and experts to remotely view the site from the onsite workers’ perspective. For organizations with locations all over the world, this eliminates the need for costly international travel of multiple stakeholders.

This can greatly improve first-time resolution times, increase first-time fix rates or faster completion of site acceptance testing. This means reducing downtime and being productive sooner and faster.

Hands-Free Computing Key Benefits

• IP66 rated /Drop proof /Dust Proof

• Explosion Proof (intrinsically safe model only)

• 8-10 hour battery life (hot swappable for HMT-1 only)

• Install virtually any Android application

• Large ecosystem of remote mentor applications

• Drive process compliance and quality

• Lower time to access information

• Use hands-free while wearing gloves

• Workaround to travel restrictions

• Maintain situational awareness

• Bring knowledge to operator at the exact moment of need

Solution Specific HMT Accessories

Communicating in a manufacturing plant can be challenge. Watch as Team RealWear visits a Harley dealership for a face-off between an iPhone and RealWear’s head-mounted Android device, testing noise cancellation while remotely collaborating and running a ten-point inspection of a Harley bike.

Watch specialists from Washington based Seaport Steel use the RealWear HMT-1 to aid work in steel cutting, inspections, and machine maintenance and troubleshooting. The Messer Group’s solution, compatible on the RealWear HMT-1 and other wearable technology or smart glasses, allows a user to navigate their device with voice commands to speed up digital workflow in field maintenance.

We can help you deploy hands free solutions for Manufacturing.