The collaboration is set to highlight "superior" levels of scalability, performance, and control for XR ready businesses
In the high-speed, high-volume world of packaging manufacturing, seconds matter, tolerances are tight, and small mistakes scale fast. Digital Work Instructions (DWIs) bring clarity, consistency, and speed to the shop floor—without slowing production.
Here’s how they make a measurable impact.
1. Changeovers Become Faster and Repeatable
Packaging lines frequently switch SKUs, formats, and labeling configurations. Every changeover is an opportunity for delay or error.
Work instructions provide:
- Step-by-step visual guidance for machine adjustments
- Clear sequencing for tooling, guides, and settings
- Standardized procedures regardless of shift or operator
Outcome: Dramatically reduced changeover time, less unplanned downtime, and faster return to full throughput.
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We’re already demonstrating the effectiveness of Manifest in enhancing accuracy, consistency, and operational efficiency for clients including British Airways and the U.S. Army, Navy, and Airforce, and Hololight will take us to the next level with customers like these.
The Hololgiht streaming integration aims to boost workers’ accessibility to AR instructional tools regardless of their location and bandwidth.
Florian Haspinger, CEO of Hololight, also added:
2. Scrap and Waste Are Caught Before They Scale
A small defect in packaging can quickly turn into thousands of wasted units.
AI-powered, work instructions help operators:
- Visually compare “good vs. bad” seals, folds, and alignments
- Validate setup quality before full-speed production
- Identify issues early, not after QA rejects a batch
Outcome: Lower scrap rates, reduced material waste, and more predictable quality output.
3. Compliance Is Enforced in the Workflow, Not After the Fact
In food, beverage, and pharmaceutical packaging, compliance isn’t optional.
Work instructions can:
- Require digital sign-offs at critical steps
- Capture photos of batch codes, labels, or seals
- Prevent progression if required steps aren’t completed
Outcome: Built-in traceability, cleaner audits, and reduced risk of recalls or compliance violations.
4. Maintenance and Troubleshooting Become Faster and More Precise
Packaging equipment, like palletizers, cartoners, and form-fill-seal machines, is complex and expensive to keep offline.
Work instructions can help support maintenance teams with:
- Visual troubleshooting steps tied to specific machines
- Exploded diagrams or AR overlays for component identification
- Standard repair procedures that reduce trial-and-error
Outcome: Faster mean time to repair (MTTR) and improved Overall Equipment Effectiveness (OEE).
5. Tribal Knowledge Is Captured Before It Walks Out the Door
Many packaging plants rely on a small group of highly experienced operators and work instructions help capture and document their knowledge.
- Capture best practices directly from experts
- Make that knowledge available across shifts and sites
- Reduce dependency on a few key individuals
Outcome: Greater workforce resilience and easier onboarding of new operators.
6. Training Happens on the Line Without Slowing the Line
Pulling operators off production for training is costly.
AI-powered work instructions enable:
- On-the-job, self-paced learning
- Immediate reinforcement of correct procedures
- Less shadowing and fewer interruptions to senior staff
Outcome: Faster time-to-competence with minimal impact on throughput.
7. Multilingual Support Improves Safety and Execution
Packaging facilities often operate with multilingual teams.
DWIs allow:
- Instant language switching on the same instructions
- Consistent safety messaging for all workers
- Reduced misunderstandings during critical tasks
Outcome: Safer operations, fewer errors, and better inclusion across the workforce.
8. Continuous Improvement Becomes Data-Driven
Unlike paper SOPs, DWIs generate insight.
Leaders can see:
- Where operators slow down during changeovers
- Which steps cause the most errors or rework
- How long tasks actually take versus expectations
Outcome: Targeted process improvements and faster operational optimization.
The Bottom Line
For packaging manufacturers, AI-powered, Digital Work Instructions turn variability into consistency and complexity into repeatable execution that unlocks higher throughput, better quality, and more resilient operations.
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