Digital Technical Assistance for Maintenance and Format Changeover
September 2021
Overview
The evolution of the Industry 4.0 paradigm has accelerated interest in applying digital technologies to industrial environments to optimize production processes. Among these technologies, augmented reality (AR) has emerged as a powerful tool.
This pilot project was launched to study, develop, and test an effective AR-based solution to support maintenance activities during in-line format changeover at Mutti. In Mutti’s industrial context, optimizing format changeover is strategically critical, as it represents a key point in production continuity and efficiency.
Mutti’s manufacturing process—spanning from raw material harvesting through processing and packaging—operates under strong seasonal pressure. Peak production periods demand maximum responsiveness to ensure product quality while maintaining high throughput. In this environment, speed, precision, and continuity during format changeovers are essential.
Project Partnership
At the end of 2020, Mutti and Vection Technologies began collaborating on a structured plan to test the application of augmented reality in industrial operations. The initiative was designed as a pilot project, serving as a test bed for the validation and adoption of digital technologies to support format changeover activities on production lines.
The project was promoted and supported by Mutti’s Industrial Direction, recognizing its strategic importance for long-term operational excellence.
Project Goals
The project had two primary goals:
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Optimize format changeover
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Perform changeovers in the best possible way and as quickly as possible.
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Maintain production continuity while improving accuracy and consistency.
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Enable knowledge sharing
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Extend specialized competencies from a small group of experts to a broader pool of operators.
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Ensure procedures could be executed by personnel who are not permanently assigned to a specific line.
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The overarching objective was to share operational knowledge, allowing the company to manage competencies centrally, maximize efficiency, and maintain uninterrupted production capability.
Activities and Methodology
To achieve these goals, existing procedures had to be revised, completed, and fully digitized. This enabled their use through Vuzix M400 augmented reality smart glasses, allowing operators to access instructions directly in their field of view.
Project Phases
From a planning perspective, the project followed these steps:
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Assessment evaluation
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GANTT definition of the project
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Field testing with two format changeovers
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Pre-pilot
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Pilot
Assessment Evaluation
This phase focused on:
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Awareness of project goals, available resources, and operator profiles
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Analysis of existing procedures and how they were currently accessed
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Evaluation of the proposed digital solution and new procedure formats
Procedure Redesign and Digitalization
Procedures were reformulated and enriched with:
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Photographic documentation
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Video recordings captured directly on the production line
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Step-by-step breakdowns of all changeover phases
This content was digitized to enable hands-free access through AR smart glasses.
Field Testing & Pre-Pilot
Two real format changeovers were used to:
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Validate procedure accuracy
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Test usability of the AR interface
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Gather operator feedback
A pre-pilot phase followed, consisting of a full day of stress testing and fine-tuning, both on the production line and in classroom settings.
The Pilot
The pilot took place on June 3, 2021, at Mutti’s Montechiarugolo plant.
For the first time, format changeover activities were performed by personnel not normally assigned to that production line, using only:
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Digitized procedures
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Vuzix M400 AR smart glasses
Operators carried out:
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Disassembly
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Retooling
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Machine setup (depalletizer, filler, capper, labeler, shrink wrapper)
Key Operational Benefits
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Operators followed certified Mutti procedures without diverting attention from their work.
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Instructions were visible directly in the field of view.
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Hands remained free, improving efficiency and safety.
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A backend system enabled:
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Operator log-on tracking
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Monitoring of completed operations
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Ongoing procedure updates and optimization
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Key Results
Monitoring during the pilot produced unanimously positive results. The most significant outcomes included:
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Completion times comparable to expert personnel
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No issues during machine retooling
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Rapid learning of procedures
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Clear and intuitive instructions
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Continuous, on-site access to documentation
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Immediate familiarity with smart glasses
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Positive ergonomic evaluation and versatility of use
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Improved compliance with safety procedures
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Reduced need for dedicated changeover personnel
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Successful changeovers by non-specialized staff
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Fewer personnel movements between lines
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Full operational continuity throughout activities
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Initial skepticism toward digital tools was fully overcome by all involved personnel
Final Comments and Next Steps
The project delivered results that exceeded initial expectations.
Beyond functional success, the pilot demonstrated strong motivational and training benefits. Operators perceived the solution as a tool for professional growth rather than a replacement for experience.
The project confirmed that:
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Technology enhances human expertise rather than replacing it
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Knowledge can be standardized and shared effectively
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AR solutions are viable for regular use in industrial format changeover
Future Outlook
Given the success of the pilot, Mutti and Vection plan to:
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Extend the solution to additional lines and plants
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Explore broader applications in industrial operations
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Develop a structured roadmap for adopting augmented and virtual reality technologies across business processes
Acknowledgments
This project was made possible through strong collaboration, trust, and team spirit between Mutti and Vection. The commitment to innovation and the willingness to test new technologies played a key role in turning the initial vision into a successful reality.