Piloting AR work instructions on a critical changeover is one of the best ways to demonstrate value and build momentum for broader adoption. A well-designed pilot delivers measurable results, generates buy-in and provides learning for scale.
This guide walks you through how to plan, execute and evaluate an AR work instruction pilot on a critical changeover.
Why pilot on a critical changeover?
Critical changeovers are ideal pilot candidates because:
- High visibility: Success on a critical changeover gets attention from leadership and operators
- Measurable impact: Improvements in time and error rates are clear and quantifiable
- Real-world validation: A critical changeover tests AR work instructions under realistic conditions
- Quick learning: Feedback from operators highlights what works and what needs improvement
Phase 1: Planning the pilot
Select the right changeover
Choose a changeover that is:
- Frequent enough: You need sufficient repetitions to measure results (aim for at least 10â20 changeovers during the pilot)
- Complex enough: Simple changeovers may not show dramatic improvement
- Impactful: Improvements should matterâeither in time, quality or both
- Representative: Results should be applicable to other changeovers
Define success criteria
Before starting, define what success looks like:
- Quantitative targets: e.g. 20% reduction in changeover time, 50% fewer startup errors
- Qualitative targets: e.g. positive operator feedback, willingness to expand
Assemble the pilot team
Include:
- Subject matter experts: Operators who know the changeover well
- Operations stakeholders: Supervisors, planners, managers who care about results
- IT/technology support: For device setup and troubleshooting
- Change management support: For communication and training
Establish the baseline
Before implementing AR, document current performance:
- Average changeover time
- Changeover time variability (range, standard deviation)
- Error rate and startup issues
- Operator feedback on pain points
Phase 2: Creating AR content
Document the standard procedure
Work with subject matter experts to define the best-practice changeover procedure. This becomes the basis for AR content.
Build AR work instructions
Convert the procedure into AR format:
- Structure into clear, sequential steps
- Add visual cues, overlays and annotations
- Include checkpoints and evidence capture at critical points
- Embed tips, warnings and best practices
Validate with experts
Have the subject matter experts review and test the AR work instructions. Refine based on their feedback.
Deploy devices
Set up AR devices (smart glasses, tablets or smartphones) at the pilot workstation. Ensure connectivity and access to the AR platform.
Phase 3: Running the pilot
Train operators
Provide brief training to pilot operators:
- How to access and navigate AR work instructions
- What to do if they encounter issues
- How to provide feedback
Execute pilot changeovers
Have operators perform changeovers using AR guidance. For each changeover, track:
- Total changeover time
- Time per step (if available)
- Errors, issues or deviations
- Operator feedback
Gather feedback
After each changeover (or weekly), collect feedback from operators:
- What worked well?
- What was confusing or difficult?
- What improvements would help?
Phase 4: Evaluating results
Compare to baseline
After sufficient pilot changeovers (aim for 10â20), compare results to baseline:
- Average changeover time: improved, same or worse?
- Variability: more consistent or still variable?
- Error rate: fewer issues at startup?
- Operator feedback: positive, negative or mixed?
Identify improvements
Based on feedback and data, identify improvements to AR content:
- Steps that need clarification
- Missing information or tips
- Pacing or sequencing issues
Make the scale decision
Based on pilot results, decide next steps:
- Scale: Expand AR work instructions to additional changeovers or lines
- Refine: Address issues identified during pilot, then re-pilot
- Pause: If results are not promising, investigate root causes before proceeding
Pilot success factors
Successful changeover pilots share common characteristics:
- Clear scope: Focused on a specific, defined changeover
- Engaged operators: Operators are involved, trained and motivated
- Realistic expectations: Pilots are learning opportunities, not perfection
- Rapid iteration: Content is refined quickly based on feedback
- Stakeholder communication: Results are shared with leadership and teams
Getting started
If you want to pilot AR work instructions on a critical changeover, start with the steps above. Define your scope, build content, run the pilot and evaluate results.
Learn more about AR-guided changeover to reduce downtime or contact ActARion to discuss your pilot plans.