Industrial teams regularly face procedures that, while rare, carry significant risk. Complex changeovers, emergency shutdowns, confined space entries, and critical maintenance tasks demand absolute precision. Yet, because these procedures are performed infrequently, even experienced technicians and operators can struggle to recall exact steps, increasing the risk of errors, incidents, and downtime.
Augmented reality (AR) work instructions offer a practical, proven way to standardise these rare or high risk procedures—making work safer, more consistent, and easier to audit.
Why rare and high risk procedures remain a challenge
Most industrial sites have robust standard operating procedures (SOPs) for daily tasks. But rare or high risk procedures create unique challenges:
- Technicians may not have repeated exposure to the steps, so memory fades.
- Paper-based SOPs can be overlooked, misinterpreted, or outdated.
- Verbal handovers lose detail, especially across shifts or teams.
- High risk tasks often require rapid, correct action under pressure.
- Auditors and safety leads need clear evidence of compliance and training.
For example, a chemical plant may only perform a full vessel decontamination once a year. A water utility might only isolate major pipelines during emergency repairs. In these cases, a single mistake can lead to injuries, environmental incidents, or costly downtime.
Research from the Institution of Chemical Engineers (IChemE) highlights that rare procedures are disproportionately represented in incident reports, largely due to lapses in memory, unclear instructions, or incomplete handovers (IChemE, 2020).
Why now: regulatory and workforce trends increase the need for standardisation
Several trends are converging to make standardisation of rare and high risk procedures a top priority:
- Stricter regulatory requirements for evidence-based training and procedural compliance.
- Aging workforce and increased turnover, leading to loss of institutional knowledge.
- More complex equipment and interconnected systems, raising the stakes for error.
- Digital transformation mandates, requiring traceable, auditable processes.
For operations managers, HSE leads, and training professionals, relying on static documents or informal coaching is no longer enough. Digital solutions that deliver guidance at the point of work—and capture proof of execution—are now essential for operational excellence.
How AR work instructions support safer, more consistent execution
AR work instructions combine visual, step-by-step guidance with real-time data and context. Delivered via smart glasses, tablets, or mobile devices, they overlay digital instructions onto the physical workspace, making each step clear and unambiguous.
Key features include:
- Visual overlays: Diagrams, animations, and markers that show exactly where to act.
- Interactive checklists: Require confirmation or input before proceeding.
- Embedded reference materials: Safety data sheets, equipment manuals, or video clips.
- Contextual prompts: Adapt instructions based on sensor data or operator input.
- Automated documentation: Capture time-stamped records, photos, and digital sign-offs.
This approach addresses the core risks of rare or high risk procedures:
- Reduces reliance on memory or paper.
- Ensures critical steps are not skipped or performed out of sequence.
- Supports less experienced team members with just-in-time knowledge.
- Provides real-time support for troubleshooting or escalation.
Note: A 2022 study by the Fraunhofer Institute found that AR-guided procedures reduced error rates by 40% and improved procedural compliance by over 30% in pharmaceutical and chemical manufacturing.
Use cases: where AR SOPs make the biggest impact
AR work instructions are particularly valuable for procedures where the stakes are high and repetition is low. Common industrial use cases include:
Emergency shutdowns and lockout/tagout (LOTO)
When a line or facility must be safely powered down, every step matters. AR SOPs guide technicians through the correct sequence, confirm each isolation point, and record proof of execution—minimising the risk of accidental energisation.
Confined space entries
AR-guided checklists ensure all pre-entry safety checks, atmospheric tests, and permit requirements are completed and documented before anyone enters a vessel or tank. Visual overlays help identify access points and hazards.
Critical maintenance and calibrations
For tasks like pressure relief valve replacement or instrument calibration, AR SOPs show the correct tools, torque values, and sequence—reducing the risk of leaks, contamination, or misalignment.
Complex changeovers and commissioning
During product changeovers or equipment commissioning, AR work instructions help teams avoid cross-contamination, missed cleaning steps, or configuration errors, especially when procedures are infrequent.
Incident response and troubleshooting
AR SOPs can provide immediate, step-by-step guidance during fire alarms, chemical spills, or equipment failures—helping operators respond correctly while capturing an audit trail for later review.
Results: measurable improvements in safety, quality, and training
Industrial companies using AR work instructions for rare or high risk procedures report concrete benefits:
- Fewer incidents: Lower rates of procedural errors and near-misses.
- Improved compliance: Digital records for audits and regulatory reporting.
- Faster onboarding: New technicians become competent in complex tasks more quickly.
- Reduced downtime: Quicker, more reliable execution of critical tasks.
- Increased workforce confidence: Teams feel supported when tackling unfamiliar or stressful procedures.
A leading energy utility implemented AR SOPs for annual transformer maintenance. The result: 100% procedural compliance, zero incidents, and a 25% reduction in task duration compared to previous years.
Similarly, a pharmaceutical packaging site used AR-guided work instructions for rare line changeovers, reducing deviation reports by 60% and cutting changeover time by 15%.
What ActARion brings to standardising rare or high risk procedures
ActARion works with industrial companies to digitise and deploy AR SOPs for critical procedures. Our approach focuses on:
- Process mapping: Collaborate with your SMEs to capture every step, risk, and control.
- Content creation: Develop clear, visual instructions tailored to your equipment and environment.
- Device selection: Advise on the right hardware—smart glasses, tablets, or mobile—based on your safety and operational needs.
- Change management: Support stakeholder engagement, training, and governance.
- Integration: Connect AR SOPs with your EHS, CMMS, or training systems for seamless documentation.
We prioritise measurable ROI: fewer incidents, higher audit scores, reduced downtime, and faster workforce readiness. Our platform is designed for easy updates as procedures evolve, ensuring your teams always have the latest, verified guidance at hand.
Addressing practical concerns: hardware, adoption, and content
Implementing AR work instructions for rare or high risk procedures raises valid questions:
- Hardware compatibility: Modern AR platforms support a range of intrinsically safe devices for hazardous environments. We help you select and pilot the right option.
- User adoption: Initial training is essential. Our experience shows most technicians adapt quickly, especially when instructions are clear and the benefits are evident.
- Content creation: Digitising rare procedures requires collaboration with your SMEs. We provide templates, workshops, and support to accelerate the process.
- Governance: Version control, access permissions, and audit trails are built in. You control who can view, execute, or update each procedure.
Note: For more on device selection and integration, see AR hardware for industrial environments.
Explore this in your organisation
AR work instructions make it practical to standardise rare or high risk procedures, improving safety, compliance, and operational confidence. If you manage teams responsible for complex, infrequent tasks, ActARion can help you explore how digital SOPs would work in your context.
Schedule an exploratory call to discuss your specific procedures, or request a demo focused on a high risk workflow. This is a chance to see the benefits—no commitment required.
Learn more about AI and AR–guided work instructions or see how digital SOPs support HSE compliance. For background on AR adoption in industry, see Harvard Business Review's overview.