Air conditioning and refrigeration (ACR) equipment is important in so many aspects of life that keeping products fully functional is vital. And yet this isn’t always easy, with many products involving complex parts. When problems do occur, manufacturers and their customers rely on skilled professionals to fix equipment as quickly as possible.

One of the biggest barriers holding engineers and maintenance teams back is out-of-date information that is difficult to comprehend. Static instruction manuals are often at the root of this and a huge source of frustration that can cause mistakes, confusion and unnecessary downtime of vital equipment.

Getting it right first time - if you’ve ever attempted to build flatpack furniture, you’ll know that static 2D drawings can only take you so far, with many of us opting for something more dynamic, such as a YouTube tutorial. It’s no different for professional repair and maintenance teams. The adoption of digital twin technology, however, is helping to deliver a more true-to-life visual experience. Hosted on online platforms, these digital 3D replicas enable engineers to rotate models to align with their view of the product in front of them, as well as zoom in for a closer inspection of the product’s various components. This is most powerful when combined with animations that help engineers follow step-by-step instructions, showing how all the parts within a product fit together. This helps avoid time-consuming mistakes, complete repairs faster, and reduce downtime. 

Up-to-date information - Another big challenge with traditional manuals is that they quickly become outdated. An engineer may be trying to assemble a product or fit a replacement part, only to realise that they are working from old guidance. In these circumstances, the issue becomes apparent only when an error is made, which is both frustrating and time-consuming. With digital assets, however, instructions can be updated with the latest information in near real-time and distributed to anyone who needs access in a single click. Being able to make changes quickly means manufacturers can be agile. They can more easily adapt instructions based on feedback from processes and operators across assembly and repair, as well as providing multi-language support as needed. Organisations can also democratise this process by encouraging engineers to offer their feedback, including best practice advice and safety notes. Each of these can be attached back to an author login for full accountability. 

Supporting training and personal development - Embracing a digital approach is also driving benefits across training and ongoing personal development. One way this can be realised is by moving away from conventional training practices, including off-site training, which can be costly and inefficient. Instead of taking staff out of the workplace for days at a time, digital platforms are enabling on-the-job training. Often referred to as ‘learning in the flow of work,’ this can help to support engineers when they are in situ and need it most. Organisations can also control how users view instructions - for example, only allowing users to see specific steps rather than the entire instruction. This can be a powerful tool when onboarding new team members.

Elevating work instructions with digital twin 3D models enables manufacturers to support their teams better and make it easier for them to understand the guidance needed to assemble, maintain, and repair equipment. This is a win-win that benefits everyone: engineers are empowered and work instructions are more engaging, while manufacturers experience a boosted reputation and increased return business.