Industrial Augmented Reality: A Growing Solution for Remote Support and Training

Industrial augmented reality (AR) is moving beyond a novelty, becoming a strategic tool for training, maintenance, and remote support in factories and plants.

• Industrial AR is no longer a buzzword; its adoption is accelerating.
• Despite higher upfront costs, plant restrictions and the shift to remote work are driving demand for AR‑enabled support.
• As vendors and operators build tailored solutions, the range of AR applications in industry will continue to expand.

Interest in industrial AR has surged in 2020, signalling a shift toward mainstream deployment.

For years, AR was seen as a technology showcase, but its potential for overlaying digital instructions onto real‑world equipment has long been recognized. Yet, like virtual reality (VR), early challenges—user acceptance, limited hardware, and cost—held back widespread implementation.

Industry veterans note that while many companies experimented with AR in the 1990s, true mass deployment remained elusive. “We’ve seen pilots, but not sustained rollouts,” says Alex West, senior principal analyst at Omdia’s Industrial IoT segment.

Consumer successes—Pokémon GO, Snapchat lenses—have proven AR’s appeal, but consumer failures such as Google Glass and the recent decline of Magic Leap remind us that hardware and use‑case fit are critical. Daqri’s exit last year is another cautionary tale.

In the industrial context, AR’s early association with gaming raised doubts. Andrew Ellis, director of global information software technical consultants at Rockwell Automation, recalls, “It looked cool for Industry 4.0, but who would actually use it?”

Randall Kerr, senior strategic account manager at Digi International, observes that AR is still nascent but “capabilities have grown dramatically in the past few years.”

ARC Advisory Group reports that the industry’s AR market is expanding rapidly, especially as remote work intensifies. “There’s a huge opportunity to train workers without bringing them into the facility,” says Richard Howells, vice president of solution management for digital supply chain at SAP.

Ellis points out that the learning curve is significant: “Just as data historians took decades to mature, AR adoption will require education and clear value paths.”

IDC forecasts a 78.5 % rise in global AR/VR spending in 2021, while ARC predicts industrial AR will grow at a 20 % CAGR. The COVID‑19 pandemic has further accelerated interest, Ellis notes.

Overcoming Cost and Integration Challenges

Historically, AR headsets were bulky, underpowered, and costly—often thousands of dollars. Comfort and battery life were also concerns, West notes.

Hardware is evolving. Newer headsets offer lighter designs and better ergonomics. RealWear’s HMT‑1, for example, meets Class I, Division 1 electrical safety standards, making it suitable for hazardous environments.

Price tags remain a barrier: the HMT‑1 retails at $2,520, while Microsoft HoloLens 2 starts at $3,500 and can reach $5,000 with developer licensing.

Kevin Doyle, vice president of commercial digital solutions at Ecolab, highlights that supporting 10,000–12,000 field technicians can drive up costs quickly.

Developing bespoke AR applications is another hurdle. “There aren’t many turnkey solutions yet,” Kerr explains.

AR for Remote Support and Service

Despite upfront costs, many companies justify AR through remote support, especially during COVID‑19. “We heard customers say, ‘That’s expensive,’” Doyle recounts. “Now they say, ‘After a month’s worth of travel, we’ve already paid for it.’”

Ecolab, a leader in water, hygiene, and infection prevention, traditionally relied on travel to service over 30,000 technicians in plants ranging from refineries to food‑and‑beverage facilities.

During the pandemic, Ecolab leveraged AR to bring experts to clients virtually. “It allowed our specialists to guide customers worldwide without flights,” Doyle says.

In one case, a brewer faced significant water loss due to valve leaks. Using AR, an Ecolab technician collaborated with an account manager to walk through the plant line and pinpoint two leaking valves—an issue that would have required an on‑site visit.

While dedicated AR headsets remain pricey, organizations can opt for smartphone or tablet‑based AR when hands‑free functionality isn’t essential.

Safety remains a short‑term challenge. “Imagine a worker 50 feet up on a power line—adding AR would divert attention from a critical safety task,” Kerr warns.

In the long term, however, industrial AR is poised to expand as vendors and customers refine applications. “We’ll solve the current problems; the question is which players will endure,” Kerr concludes.

As the industry matures, AR’s role in remote support, training, and operational efficiency will only grow.