Uses and challenges of digital twins-based augmented reality in operator training and data visualization in process manufacturing lines

Despite the widespread interest in Industry 4.0 technologies, only a few empirical studies focus on augmented reality (AR) coupled with digital twins (DTs). Thus, little is known about the usefulness and challenges of these in manufacturing contexts. To address this gap in the literature, the present study conducts an action research study of a DT-based AR project in a process manufacturing company. Specifically, first, two DT-based AR applications for training new operators and live data visualizations, respectively, are developed. These applications are tested by relevant employees, who are subsequently interviewed. Through analysis of interview transcripts, four overall uses of DT-based AR are identified: (1) training of new staff; (2) data visualization; (3) plant design validation; and (4) maintenance. Furthermore, several challenges related to the use of this technology are identified, which are organized under four themes: (1) safety issues; (2) cost issues; (3) convenience issues; and (4) accessibility issues. These findings are organized into a model illustrating the relationships between the uses and challenges of DT-based AR in process manufacturing.