How a Single Augmented Reality Deployment Helped Avoid the Costs of an International Engineering Team

Client

International automotive manufacturer and one of the leading suppliers of components for the automotive industry. The company specializes in the production of advanced powertrain systems and vehicle components supplied to manufacturing facilities worldwide. The client operates in a highly automated production environment and delivers projects focused on the development and implementation of modern manufacturing lines in collaboration with international engineering teams.

Challenge

During the COVID-19 pandemic, the client faced an urgent challenge: launching a new, advanced production line. The line was designed by engineers in Japan, while its installation and configuration were carried out at the manufacturing plant in Poland.

Due to travel restrictions, the physical presence of Japanese experts was not possible. However, critical assembly stages, such as wiring complex electrical cabinets containing hundreds of cables, required precise instructions and expert supervision. Any wiring error could lead to system failures, project delays, or costly production downtime.

The client needed a solution that would enable the remote, accurate, and intuitive transfer of technical knowledge while allowing Japanese experts to supervise operators in real time from the other side of the world.

Solution

To address the client’s needs, the AR Remote Support module was implemented, powered by the nsFlow platform and RealWear industrial smart glasses. This technology enabled real-time remote support using augmented reality and audiovisual communication.

Operators in Poland were equipped with AR glasses that allowed them to work hands-free—performing tasks without interruption while remaining connected to remote experts. Key features of the implemented solution included:

Real-time video feed – Japanese engineers had continuous access to the live camera feed from the operator’s glasses.
Remote annotations on images – At critical moments, engineers could freeze the video, mark instructions (e.g., “third cable from the right”), and send annotated images to the operator.
Full audiovisual communication – Support was provided through voice and visuals, with no need for hand-held devices.
Simple setup – Consultations could start with just a link—no programming skills or complex configuration required.
Compliance with safety standards – RealWear glasses were fully compatible with industrial environments, allowing the use of helmets, gloves, and protective eyewear.

Thanks to this setup, experts could remotely supervise the assembly of the electrical cabinet—pointing out exact components and cables to connect, and correcting any errors in real time.

Four-step implementation process: device setup, platform config, expert connection, and verification.

Results

The impact of the implementation was almost immediate, delivering financial, operational, and environmental benefits:

Reduced travel and accommodation costs – Eliminating international travel (from Japan to Poland) resulted in savings of several thousand euros for each deployment iteration.
Faster implementation time – Instant access to remote experts helped avoid downtime and delays, significantly accelerating the production line launch.
Greater precision and reduced risk of errors – The ability to annotate images visually drastically reduced the risk of incorrect component connections.
Increased employee confidence – Operators felt supported and reassured by having real-time access to expert guidance—even for seemingly minor uncertainties.

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How a Single Augmented Reality Deployment Helped Avoid the Costs of an International Engineering Team

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Challenge

Solution

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