Projection-Based Augmented Reality for Lean Drone Assembly: Reducing Waste and Enhancing Learning Efficiency

This study explores the integration of Augmented Reality (AR) into Lean Manufacturing practices to enhance manual drone assembly training. Leveraging lean principles such as Jidoka, standardized work, and visual management, a projection-based AR system was developed featuring real-time task guidance, gesture control, and voice interaction. A structured methodology: Set up, Testing and Evaluation, was used to compare the performance of AR-assisted and traditional non-AR training. Participants across both conditions completed identical tasks, with results revealing that AR users completed tasks 22.3% faster and committed no defects, compared to several errors in the control group. Furthermore, learning curve analysis showed a 4.1% greater improvement in skill acquisition among AR users. By embedding lean tools directly into the AR interface, the system reduced waste related to waiting, over-processing, and errors, while enabling scalable, hands-free instruction. Although Vision-Language Model (VLM) integration remains a future enhancement, the current implementation demonstrates AR’s capacity to streamline training, improve consistency, and support workforce development within Industry 4.0-aligned environments.