Jon Reneberg’s fervent interest in human-technological integration goes beyond mere fascination; it has led him to implant two RFID chips in his body. One embedded in his right hand starts his car, while the other in his left ensures two-factor authentication for websites using VivoKey. “I am a technology nerd from end to end,” Reneberg jests.
As the lead digital manufacturing specialist at Purdue University’s Manufacturing Extension Partnership, Reneberg spearheads innovation and boasts over two decades in the manufacturing industry. He acknowledges his implants are extreme but highlights practical, less invasive wearable technologies that significantly enhance health, safety, efficiency, and environmental awareness.
Manufacturers are increasingly turning to wearables like augmented-reality (AR) glasses, exosuits, and ergonomic sensors. These devices are designed to make processes more efficient and reduce the risk of workplace injuries. In 2022 alone, the warehousing, manufacturing, and construction sectors reported more than 700,000 non-fatal injuries and over 2,000 fatalities. The U.S. Government Accountability Office suggests that wearable tech has the potential to improve safety in these areas, although more data is required to fully assess their effectiveness.
Reneberg and other experts underline the importance of correctly implementing and communicating the purposes of wearables. “Culturally, you have to prove that there’s a benefit to the employee,” Reneberg asserts, emphasizing that merely stating benefits is insufficient for successful adoption.
Enhancing Reality with Wearable Technology
AR and VR technologies offer distinct advantages on the factory floor. For example, AR glasses provide real-time data overlays during production, enhancing accuracy and reducing errors. Meanwhile, VR is invaluable for training, offering immersive experiences that simulate real-world manufacturing challenges.
Tooling U-SME’s Virtual Labs program, launched in 2022, employs VR headsets to teach basic skills through e-learning before plunging trainees into virtual manufacturing environments. This innovative approach has made training more engaging, according to Chad Schron, Senior Director at Tooling U-SME.
However, the practicality of deploying VR and MR devices on active factory floors is still debated due to safety concerns. Scope AR’s WorkLink platform, used with the HoloLens 2, enables users to superimpose work instructions and 3D designs onto real-world objects. This technology, widely adopted by aerospace and defense sectors, minimizes errors and cognitive load, thereby boosting productivity. As CEO Scott Montgomerie explains, “You’re only showing what the manufacturing engineer wants you to see right now, and it’s perfect.”
Exoskeletons and Worker Endurance
Exoskeletons and exosuits, designed to reduce injury and fatigue, require substantial workforce buy-in for successful implementation. These devices can be powered by motors with batteries or rely on spring mechanisms for assistance.
HeroWear’s Apex 2, a textile-based exosuit, engages elastic bands through a shoulder switch, easing back strain by 20 to 40 percent. Similarly, SUITX’s devices utilize springs to assist in overhead and manual labor, significantly reducing injury risks and fatigue.
Both companies emphasize the importance of training and proper deployment. “The exosuits can help you all day long in a lab, but if it’s not functionally usable by the user—it’s not going to succeed,” says Paul Nicholson, Vice President of Growth at HeroWear.
Sensors: Real-Time Data for Enhanced Safety
Wearable sensors, like those from MakuSafe, monitor air quality, heat exposure, noise levels, and more. These devices, accompanied by an analytics dashboard, offer crucial insights into workplace conditions without compromising worker privacy. “We’re not constantly annoying them, and we’re not continuously tracking people,” assures Tom West, MakuSafe’s Vice President.
Data from these sensors can yield actionable insights, such as identifying hazardous areas or revealing productivity issues, thus enabling management to make informed decisions to improve safety and efficiency.
The Future of Manufacturing
These technologies collectively contribute to the concept of Industry 4.0, integrating human and machine interactions in a smart factory environment. Reneberg sees promise in these innovations but advises patience and meticulous planning for successful implementation. “Most manufacturing is cyclical,” he notes, recommending introducing new technologies during off-peak periods to minimize disruptions.
Transparent communication and leadership buy-in are crucial. “Be honest and be respectful of people’s privacy,” Reneberg urges, advocating for management to actively participate in using these technologies.
In summary, wearable technology in manufacturing presents exciting opportunities for improving safety, efficiency, and workforce well-being. As companies navigate the adoption of these innovations, thoughtful execution and clear communication will be key to unlocking their full potential.