Modern industrial operations depend on tightly connected digital processes. Integrating AR work instructions with MES, ERP or CMMS systems is now essential for organisations seeking measurable gains in productivity, quality, and safety. For operations managers, HSE leads, and maintenance heads, this integration enables teams to follow up-to-date, context-aware guidanceâwhile capturing real-time data to drive better decisions.
Why integration matters now: context and challenges
Industrial environments are facing increased pressure to deliver safer, more efficient, and higher quality outcomes, often with leaner teams and more complex assets. Many organisations have invested in Manufacturing Execution Systems (MES), Enterprise Resource Planning (ERP), and Computerized Maintenance Management Systems (CMMS) to manage production, resources, and maintenance. Yet, gaps remain between digital planning and what happens on the shop floor.
Common pain points include:
- Operators relying on outdated paper SOPs or static PDFs.
- Delays in communicating process changes to the field.
- Incomplete, error-prone data capture during inspections or maintenance.
- Difficulty tracking compliance, training progress, or root causes of downtime.
As a result, even with robust MES, ERP or CMMS systems in place, teams struggle with inconsistent execution, avoidable errors, and missed improvement opportunities.
Why change is needed now
Several factors are making this integration urgent:
- More frequent process changes: Agile manufacturing and regulatory updates require faster SOP updates.
- Aging workforce: Critical know-how is at risk as experienced technicians retire.
- Higher compliance and reporting demands: Audits and certifications require traceable, real-time data.
- Digital transformation goals: Leadership is under pressure to prove ROI from digital investments.
Without closing the gap between digital systems and frontline execution, investments in MES, ERP or CMMS deliver limited value. Teams need actionable, up-to-date guidanceâdelivered directly where work happens and linked back to core systems.
How AR work instructions connect with MES, ERP and CMMS
AR work instructions, sometimes called AR SOPs or AI and ARâguided work instructions, provide step-by-step, visual guidance through smart glasses, tablets, or mobile devices. When integrated with MES, ERP or CMMS, they enable a closed feedback loop between planning, execution, and continuous improvement.
Key integration points include:
- Automatic job dispatch: Work orders or tasks from MES/CMMS trigger relevant AR work instructions on the technicianâs device.
- Context-aware guidance: The AR system pulls asset data, work history, and safety information from ERP/CMMS for precise, tailored instructions.
- Real-time validation: Completion data, measurements, photos, or compliance checks are sent back to MES/ERP/CMMS instantly.
- Analytics and traceability: All actions are logged, enabling performance tracking, training analysis, and audit readiness.
This integration transforms digital work instructions from static documents to dynamic, data-driven tools that boost both compliance and productivity.
Use cases: AR work instructions integrated with MES, ERP or CMMS
Integrating AR work instructions with core systems creates value across multiple industrial scenarios:
Maintenance and inspections
- Automated work order execution: A technician receives a preventive maintenance order from the CMMS. AR-guided instructions walk them through each step, pulling the latest asset data and safety procedures. As tasks are completed, results are logged automatically in the CMMS.
- Condition-based inspections: MES triggers an inspection based on sensor data. AR instructions guide the operator, ensuring the correct checks are performed and findings are captured in real time.
Production and quality operations
- Changeover procedures: ERP schedules a product changeover. AR work instructions ensure operators follow the latest sequence, reducing setup times and errors. Completion is confirmed in the MES.
- In-process quality checks: Operators receive digital work instructions for quality checks at specific production stages. Results and photos are submitted directly to MES or ERP for traceability.
Safety and compliance processes
- Lockout/tagout (LOTO): When maintenance is scheduled, AR SOPs guide the technician through LOTO steps, referencing equipment data from the CMMS. Compliance is documented with time-stamped evidence.
- Incident response: In the event of a safety incident, AR work instructions provide just-in-time guidance, while all actions are recorded for later review and compliance.
Training and onboarding
- Role-based onboarding: New technicians receive tailored AR SOPs for their first assignments, with progress and competency tracked in the L&D or HR module of the ERP.
- On-the-job upskilling: Operators access AR-guided procedures for new equipment, with completion and assessment data fed back to HR or training systems.
Results and measurable impact
Organisations integrating AR work instructions with MES, ERP or CMMS report tangible improvements:
- Reduced errors and rework: Standardised, up-to-date instructions cut avoidable mistakes by 30â60% (see Deloitte, 2022).
- Faster onboarding: New hires reach proficiency up to 40% faster with AR-guided, system-connected SOPs.
- Higher compliance rates: Automatic logging of completed steps and evidence raises audit pass rates and reduces non-conformance events.
- Better resource utilisation: Real-time feedback helps planners adjust schedules and inventory, improving OEE and reducing downtime.
- Continuous improvement: Captured execution data supports root cause analysis and ongoing SOP optimisation.
These results are supported by both industry research and ActARion client case studies, which show measurable gains in safety, productivity, and quality.
Addressing common concerns: integration, hardware and change management
Decision makers often raise valid concerns about integrating AR work instructions with MES, ERP or CMMS systems:
Technical integration
Integration can be achieved through open APIs, middleware, or connectors that bridge AR platforms and existing systems. Itâs important to:
- Map data flows and user roles.
- Ensure secure, compliant data exchange.
- Pilot with a single process or asset, then scale.
ActARion works with IT and OT teams to ensure robust, secure integrationâregardless of system vendor.
Hardware and usability
AR work instructions run on smart glasses, tablets, or ruggedised mobile devices. Key factors for deployment include:
- Device compatibility with existing IT security policies.
- Ergonomics for long shifts or hazardous environments.
- Offline capability for sites with limited connectivity.
Content creation and governance
Digitising SOPs for AR and integrating them with MES/ERP/CMMS requires structured content. Best practices include:
- Starting with high-impact, high-frequency procedures.
- Using modular templates for faster updates.
- Involving process owners and HSE/QA experts in validation.
- Setting up version control and approval workflows.
Change management and workforce adoption
Successful integration depends on:
- Training supervisors and technicians on new workflows.
- Communicating the âwhyâ and benefits early.
- Providing ongoing support and feedback channels.
- Tracking adoption metrics and celebrating quick wins.
ActARion provides structured change management support, helping teams build confidence and competence.
What ActARion brings to AR work instruction integration
ActARion specialises in helping industrial organisations connect AR work instructions with MES, ERP and CMMS systemsâsafely, securely, and with measurable results. Our approach includes:
- Process mapping: Identifying high-value integration points across maintenance, production, quality, and safety.
- Technical expertise: Secure, standards-based integration with major MES, ERP and CMMS vendors.
- Rapid content digitisation: Converting SOPs into modular, AR-ready formats, validated by your process experts.
- User-centric deployment: Supporting device selection, pilot projects, and user training.
- Continuous improvement: Analytics and feedback loops to refine procedures and drive sustainable change.
We understand the priorities of operations, HSE, maintenance, and training leadersâand work as a partner to deliver outcomes, not just technology.
Explore AR work instruction integration in your organisation
Integrating AR work instructions with MES, ERP or CMMS can deliver measurable improvements in safety, quality, and productivity for your teams. If you want to see what this could look like in your context, schedule an exploratory discovery call with ActARion. Thereâs no commitmentâjust a chance to map opportunities and see concrete examples.
- Learn more about digital work instructions for industrial maintenance.
- See how AR onboarding for technicians accelerates skills transfer.
- For more on MES, ERP and CMMS integration, see the ISA-95 standard overview.
Ready to build smarter, safer, more connected operations? Schedule a discovery call with ActARionâs experts today.