The Industrial Metaverse in Maintenance: Remote Service with AR/VR

1. Introduction: Innovations and their Importance for Industry

The rapid development of digital technologies is transforming approaches to maintenance, repair and operation (MRO) in industry. The concept of the Industrial Metaverse, which integrates the technologies of augmented (AR) and virtual (VR) reality, digital doubles and the Internet of Things (IoT), opens new perspectives for the optimization of production processes. For the Ukrainian industrial sector, which seeks to increase efficiency, reduce downtime and ensure stable operation of equipment in the face of modern challenges, the implementation of these innovations is critically important. Using AR/VR for remote maintenance allows access to expert knowledge regardless of geographic location, speeds up diagnostics and repairs, and improves personnel safety.

2. Scientific Basics: Physics and Research

Industrial Metaverse is not a single technology, but is an integration platform that combines several key components:

Digital Twins (Digital Twins): Virtual models of physical objects, processes or systems that are synchronized with real data in real time. This is enabled by IoT sensors that collect data on temperature, pressure, vibration, energy consumption and more. The ISO 23247 standard defines the framework and principles for the creation and use of digital doubles.
Augmented (AR) and Virtual (VR) Reality: AR superimposes digital information on the real world, while VR fully immerses the user in a virtual environment. XR (Extended Reality) is a broader term that encompasses both approaches. These technologies require high-precision optics, powerful graphics processors, and motion tracking systems with minimal latency (less than 20ms) to prevent motion sickness.
Broadband (5G/6G): Low latency and high bandwidth are essential for high-volume digital twin data transmission and real-time AR/VR video streaming.
Artificial Intelligence (AI) and Machine Learning (ML): Used to analyze IoT data, predict equipment failures, optimize maintenance schedules, and provide intelligent guidance to technicians in AR interfaces.
Tactile (Haptic) Feedback: Allows users to feel interaction with virtual objects, which increases the immersiveness and accuracy of remote operations.

The physical principles of AR/VR are based on optics, computer graphics and signal processing. Tracking systems (for example, SLAM - Simultaneous Localization and Mapping) allow precise positioning of virtual objects in physical space. For remote maintenance, the standardization of data exchange protocols such as OPC UA (IEC 62541) is critical, ensuring interoperability between different industrial systems and platforms of the Metaverse.

3. Current State of Development: Technology Readiness Levels (TRL)

The development of the Industrial Metaverse is at different Technology Readiness Levels (TRLs) depending on the specific application:

AR for remote assistance and training: TRL 7-8. Commercial solutions are available, widely used in pilot projects and some industrial operations. For example, remote consultation of technicians through AR headsets, which allows the expert to see what the technician sees and overlay digital instructions directly on the equipment.
VR for simulation and training: TRL 7-8. It is used to train personnel to work with complex equipment, practice emergency situations without risking life and expensive equipment.
Industrial Metauniverse integrated platforms with digital doubles: TRL 5-6. There are prototypes and demonstration systems combining AR/VR with digital doppelgangers for comprehensive monitoring and control. Used in limited pilot projects of large industrial companies.
Full Industrial Metaverse with haptic feedback and AI autonomy: TRL 3-4. It is at the stage of research and laboratory development.

The key players in this field are software developers (Siemens with Xcelerator, PTC with Vuforia, Microsoft with Dynamics 365 Guides and HoloLens), as well as hardware manufacturers (Meta, HTC, Varjo). A professional AR headset can cost between €3,500 and €10,000, while software and integration can add significant costs, reaching €20,000-€50,000 for initial deployment for a single shop.

4. Potential Impact on MRO

The application of the Industrial Metaverse has the potential to significantly change current MRO practices:

4.1. Remote Diagnostics and Troubleshooting

Expert Access: Allows experienced engineers to remotely control less skilled technicians by visualizing problem areas and providing step-by-step instructions. This reduces the time to response and resolution (MTTR) by 25-40%.
Data Visualization: AR glasses can display data from IoT sensors (eg bearing temperature 75°C, hydraulic system pressure 150 bar, pump vibration 12 mm/s) directly on the equipment, helping to identify anomalies faster.

4.2. Predictive Maintenance

Interactive Visualization: Technicians can visualize predicted failure points or areas of increased wear on a digital counterpart or directly on physical equipment via AR, enabling preventive maintenance before a critical failure occurs. This can increase overall equipment effectiveness (OEE) by 10-15%.
Optimization of Resources: Accurate forecasting of maintenance needs allows for optimization of work planning and management of spare parts stocks.

4.3. Training and Adaptation of Personnel

Immersive Simulations: VR-simulations allow for realistic training in working with complex or dangerous equipment (for example, high-voltage installations, systems under pressure up to 200 bar), reducing the risks and costs of real training.
AR-instructions: New employees can receive step-by-step AR instructions for performing standard operations, which speeds up their adaptation and reduces the number of errors.

4.4. Management of Spare Parts and Logistics

Visualization of Components: Using the AR headset, the technician can identify the required spare part, view its drawings with tolerances up to ±0.02 mm, check stock availability and even order it directly through the integrated interface.
The role of UNITEC-D: As a supplier of certified industrial spare parts, UNITEC-D provides a critical link in this chain. Integration with Industrial Metaverse platforms will allow UNITEC-D customers to quickly identify and order DSTU, EN, ISO compliant components directly from the virtual environment, reducing sourcing and delivery time. Our UNITEC-D E-Catalog is a key tool for such an integrated approach.

5. Timeline and Implementation Curve

A realistic timetable for the introduction of the Industrial Metauniverse in Ukrainian industry may look like this:

5.1. 2026-2028: Early Implementation (Pilot Projects)

Technologies: AR for remote assistance and VR for training simulations.
Application: High value or critical equipment (eg turbines, large presses, robotic lines).
ROI: Expected 15-20% reduction in downtime, 20-30% reduction in expert travel expenses.
Costs: The initial investment for an AR headset and software licenses for 5-10 users can be €50,000 – €150,000.

5.2. 2029-2032: Expansion and Integration

Technologies: Advanced AR/VR integration with existing digital twin, ERP and CMMS systems. The appearance of the first complex platforms of the Industrial Metaverse.
Application: Wider implementation on production lines, in quality control departments, for production planning.
ROI: Increase in OEE by 10-15%, further decrease in MTTR, optimization of spare parts logistics. Achieving ROI within 2-3 years.
Costs: Infrastructure expansion, additional licenses, integration work - from €200,000 to €1,000,000+ depending on scale.

5.3. 2033-2035: Maturity and Widespread Adoption

Technologies: Standardized protocols for the Industrial Metaverse (for example, based on DSTU ISO/IEC 30141 for IoT architecture), implementation of tactile feedback, real-time AI assistance.
Applications: Widespread use in MRO, design, manufacturing, supply chain management.
ROI: Further increases in productivity and security, significant reduction in operating costs.

6. Challenges and Barriers

The implementation of the Industrial Metaverse faces a number of challenges:

Technical Barriers:
- Compatibility and Interoperability: The diversity of hardware and software requires unified standards for data exchange that meet the requirements of EN 61360 (Data Types for Industrial Automation).
- Computing Power and Network: The need for high-performance computing resources (edge computing) and stable, high-speed networks (5G/6G) with low latency.
- Accuracy and Reliability: Providing high accuracy imaging and tracking for mission-critical operations.
Economic Barriers:
- High Initial Investment: Cost of hardware, software, integration, and staff training.
- Calculating ROI: The difficulty of accurately quantifying ROI, especially in the early stages.
Regulatory and Security Barriers:
- Cyber Security: Protecting industrial data and control systems from cyber attacks is essential, especially for remote access. Compliance with DSTU ISO/IEC 27001. is required
- Data Privacy: Compliance with requirements for the protection of personal and corporate data.
- Certification: The need for certification of remote operations, especially for safety-critical tasks, according to EN 61508 (Functional safety of systems).
Human Factors:
- Acceptance by Users: Resistance to change, the need for significant training and adaptation of personnel to new work methods.
- Ergonomics: Convenience and duration of use of AR/VR headsets.

7. What Plant Engineers Should Do Now

To prepare for the era of the Industrial Metaverse, engineers and business leaders should take the following steps:

Data Infrastructure Modernization: Invest in reliable IoT infrastructure, data collection and analysis systems, as well as secure high-speed networks. This includes implementing industrial communication protocols and ensuring compliance with DSTU EN 50600 standards for data center infrastructure.
Development of Digital Twins: Start creating or invest in the development of digital twins for your most critical assets. This will provide the basis for data visualization in AR/VR.
AR/VR Pilot Projects: Identify specific, limited scenarios for piloting AR/VR, such as remote assistance for one complex machine or VR training for a new production line. Start simple to demonstrate ROI.
Development of Staff Skills: Implement training programs to improve digital literacy, data analysis and basic skills for working with AR/VR interfaces.
Selecting Trusted Partners: Evaluate technology providers and MRO partners who can provide compatibility, certified components (CE, UkrSEPRO) and technical support. UNITEC-D, as a global authority in MRO, is ready to support these initiatives by providing high-quality and certified spare parts, which are the foundation for the reliable operation of equipment in any, even virtual, environment.

8. Conclusion

Industrial Metaverse and AR/VR integration in MRO is not just a futuristic concept, but a real direction of industrial development. While there are significant technical, economic and regulatory challenges, the potential benefits – reduced downtime, increased efficiency, safety and access to expertise – make this technology extremely attractive. For Ukrainian industrial enterprises seeking to remain competitive and sustainable, strategic planning and gradual implementation of these innovations is essential. In this process, ensuring the physical reliability of the equipment through the use of certified components remains a constant priority.

For DSTU, EN, ISO certified industrial spare parts and components, visit UNITEC-D E-Catalog.

9. Links

ISO 23247:2021. Automation systems and integration — Digital twin framework for manufacturing.
IEC 62541 (OPC UA): Open Platform Communications Unified Architecture.
EN 61508:2010. Functional safety of electrical/electronic/programmable electronic safety-related systems.
DSTU ISO/IEC 27001:2015. Information technologies. Safety methods and means. Information security management systems. Requirements
DSTU EN 50600:2018. Infrastructure of data processing centers.
EN 61360:2017. Standard data element types with associated classification scheme.
Industry 4.0 and the Metaverse: A New Era of Industrial Transformation. Fraunhofer Institute for Industrial Engineering IAO. 2023.