Checklist: is your assembly process ready for AR work instructions?

AR work instructions can dramatically reduce assembly errors, improve consistency and accelerate onboarding. But not every assembly process is equally ready for AR—and a poorly planned implementation can waste time and resources.

This checklist helps you assess whether your assembly process is ready for AR work instructions, what prerequisites you need in place and what success factors to consider before starting.

Part 1: Process characteristics

Assess whether your assembly process has the characteristics that benefit most from AR guidance.

✓ Procedural and repeatable tasks

AR work instructions work best for tasks that follow a defined sequence. If operators perform the same steps in the same order, AR can guide them reliably.

Ask yourself:

• Are assembly tasks documented as step-by-step procedures?
• Do operators follow a consistent sequence, or is the process highly variable?

✓ Visual complexity

AR guidance adds the most value when visual context matters—where to place a component, how to orient it, which fastener to use.

Ask yourself:

• Would visual overlays, arrows or 3D models help operators understand what to do?
• Are there frequent errors related to orientation, placement or identification?

✓ Variant complexity

High-mix, multi-variant assembly is a strong candidate for AR. Operators must switch between different configurations, and mistakes are common.

Ask yourself:

• How many product variants do operators handle?
• Are variant-specific differences a common source of errors?

✓ Quality and traceability requirements

If you need to document every step, capture evidence or trace builds back to specific procedures, AR work instructions provide built-in support.

Ask yourself:

• Are you required to document assembly steps for audits or compliance?
• Do customers or regulators require traceable build records?

Part 2: Existing documentation and knowledge

Assess the state of your current work instructions and expert knowledge.

✓ Documented SOPs or work instructions

AR content is easiest to create when existing documentation is available. If procedures exist only in experts' heads, you will need to capture them first.

Ask yourself:

• Do written SOPs or work instructions exist for target assembly tasks?
• Are they accurate and up to date?

✓ Access to subject matter experts

Even with documentation, expert input is essential for creating effective AR content. Experts can validate steps, add tips and identify common mistakes.

Ask yourself:

• Are experienced operators available to support content creation?
• Are they willing and able to contribute time?

✓ Clear ownership and governance

Someone needs to own the AR content—keeping it current, responding to feedback and managing updates as processes change.

Ask yourself:

• Who will own and maintain AR work instructions after launch?
• Is there a process for updating content when procedures change?

Part 3: Technology and infrastructure

Assess your technology readiness.

✓ Device availability

AR work instructions run on smart glasses, tablets or smartphones. You need devices available for operators to use.

Ask yourself:

• Do you have devices (or budget for devices) for the target assembly stations?
• What device type fits best—smart glasses, tablets, fixed displays?

✓ Connectivity

AR platforms typically require network connectivity for content delivery, updates and data logging.

Ask yourself:

• Is Wi-Fi or cellular available at assembly workstations?
• Are there security or IT constraints on device connectivity?

✓ Integration with production systems

For best results, AR work instructions should integrate with your MES, ERP or quality systems—pulling order data and logging results automatically.

Ask yourself:

• Do you want AR to pull order or variant data from production systems?
• Is integration technically feasible and supported by your IT team?

Part 4: Organisational readiness

Assess whether your organisation is ready to adopt AR work instructions.

✓ Stakeholder support

AR implementation requires buy-in from operations, quality, training and IT. Without support, adoption will stall.

Ask yourself:

• Do key stakeholders understand and support the initiative?
• Is there executive sponsorship to drive change?

✓ Change management capacity

AR work instructions change how operators do their jobs. Change management—communication, training, support—is essential.

Ask yourself:

• Do you have resources for change management?
• Are supervisors and trainers ready to support adoption?

✓ Clear success criteria

Know what success looks like before you start. Define metrics and targets so you can measure results objectively.

Ask yourself:

• What metrics will you track (e.g. error rate, cycle time, First Time Right)?
• What improvement would justify broader rollout?

Summary: readiness scorecard

Use this simple scorecard to summarise your readiness:

If most categories are ready, you are well-positioned for a successful pilot. If some need work, address gaps before starting. If multiple categories are not ready, consider a smaller scope or additional preparation.

Next steps

If your assembly process passes this readiness checklist, you are ready to explore AR work instructions. Start with a focused pilot on a defined set of tasks, measure results and build from there.

Learn more about AR-guided assembly for error-free production or contact ActARion to discuss your assembly challenges.