27 www.drivesncontrols.com October 2025 AUGMENTED REALITY n real-time guidance and error-checking systems. For instance, the aerospace giant Safran is using AR to ensure precision when it assembles aircraft landing gear. The result? Higher-quality output with a significantly lower defect rates – which impacts both product reliability and customer satisfaction. AR addresses multiple cost points, from accelerating employee training to reducing material waste and production downtime. Training new operators often involves weeks of supervision as well as costly downtime. The use of AR tools on the shopfloor can shorten onboarding times by up to 50%, enabling workers to gain hands-on skills in real-world scenarios without the risk of costly errors. Beyond the quantifiable numbers, AR delivers more than just measurable results – it creates indirect benefits that increase its value over time. Comfort and Safety Augmented reality improves workplace comfort by simplifying complex tasks and reducing cognitive loads significantly. This allows employees to focus more effectively on their responsibilities, leading to improved job satisfaction and increased retention rates. A more comfortable and supportive work environment fosters longterm commitment. Additionally, AR enhances safety by providing real-time warnings within an operator’s field-of-view, thus helping to prevent accidents. By streamlining processes and prioritising employee well-being, AR creates a safer, more efficient, and more satisfying workplace. AR also impacts end-users by improving manufacturing quality, delivery timelines and communications. For example, Latecoere – a leading manufacturer of aerostructures – is using AR for inspections, and is achieving faster turnaround times without sacrificing quality. The technology also allows precise referencing of operational performance in inspection reports, which become part of a product’s delivery documentation. In the end, customers receive better products, faster, and with enhanced traceability, creating loyalty and trust. AR can also be a stepping stone towards Industry 4.0, where automation, IoT, and data-driven processes dominate. Early adopters of AR can gain a competitive edge, demonstrating that they’re willing to innovate and bring cutting-edge practices to their activities. This boosts their brand image and can help to attract talent in a competitive job market. Also, showcasing digital tools appeals to younger professionals and positions a company as being innovative. Evaluating the ROI Integrating AR into your operations is an investment and, like any investment, it is essential to be able to measure its ROI. Here’s a roadmap to evaluating AR’s financial and operational impact: n Define clear objectives Pinpoint the operational inefficiencies or pain points that AR will address. n Select ROI metrics Choose meaningful benchmarks, such as improvement in throughput or reduction in errors, training time, or material waste, or improved throughput or “right first time.” n Determine the optimum technology for your application Companies new to AR technology often assume that smart glasses are the only available technology. There are actually several available technologies, including projection systems, smartphones and digital cameras. It’s important to choose the best technology for your application to maximise its potential benefits and return on investment. n Calculate costs Include hardware (such as AR glasses), software, training, integration and support costs. n Measure outcomes Compare preimplementation metrics with the results obtained after AR adoption, and look for both direct and indirect benefits. n Monitor and optimise ROI is never static; it evolves as your AR implementation adapts alongside your existing operations. Periodic assessments ensure that the technology keeps delivering value. Investing in AR without a clear methodology for ROI evaluation, risks missed opportunities – or worse, wasted budgets. A thorough examination will help you see whether AR is delivering on your goals. Manufacturers adopting AR technologies have reported transformative results in a variety of sectors. For example: n One of our customers in the aerospace and defence sector has reported a 34% increase in assembly speeds and avoided non-conformance issues for complex parts since implementing AR. n A leading commercial truck manufacturer deployed Delmia’s augmented experience to help it with the assembly of harnesses. By projecting the harness path directly onto the assembly table, it was able to halve takt times, as well as cutting reworking by 80%, thus boosting both throughput and quality. n The aerospace manufacturer Latecoere adopted AR for quality inspections. Compared to traditional methods, the ARdriven approach cut inspection times by up to 30% and identified issues more quickly, reducing rework costs substantially. n Safran, another aerospace supplier, has implemented AR across numerous parts of its group activities. For example, it is using AR for assembling aircraft landing gear. Inspections are said to be four times more efficient after embracing the AR technology, and non-quality costs for paint masking operations have been reduced by a factor of seven. n Since implementing an AR system, an industrial equipment manufacturer has reported that there are now no nonconforming parts reaching the next station in its operations. n A major aeronautics manufacturer that used to mark its parts manually before proceeding to assembly, has cut its preparation time from two hours to a few minutes by implementing AR-guided projection systems that have radically accelerated production times. These diverse, quantified results are repeated across various sectors, proving that AR isn’t just a future promise, but a presentday catalyst for measurable operational gains. The ROI of AR isn’t a promise – it’s a proven outcome for manufacturers that are prepared to innovate. From speeding up assembly lines to improving inspections and customer experiences, AR shows its worth consistently. It’s both a short-term game-changer with immediate benefits, and a long-term player in building competitive advantage. For manufacturers looking to stay ahead, AR is a strategic investment, not a luxury. The question isn’t if AR offers ROI, but how quickly you can integrate it into your operations to experience the results. It’s time to evaluate the numbers and unlock AR’s potential. n The aerospace manufacturer, Safron, has used AR to improve inspection speeds
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