Investigating the Impact of Augmented Reality Instruction Modes for Manual Wire Harness Assembly Task on Formboards

Wire harness assembly is a highly manual job performed on formboards. Augmented reality (AR)-assisted wiring operations can improve work efficiency and reduce operator workload. However, investigations into the effects of AR-assisted wiring assembly on operator performance remain in the preliminary stage. To investigate how different AR wire harness modes support novice operators in completing assembly tasks effectively, this exploratory laboratory study examined the impacts of AR instruction modes for single-route conditions on assembly performance (task time and number of assembly errors), gaze behavior using eye-tracking data, and subjective experience measured with the NASA-TLX (Task Load Index) as a post-experiment questionnaire in a controlled laboratory environment. Three wire path visualization modes, i.e., static color mode (SCM), dynamic color mode with flashing display (DCM-FD), and dynamic color mode with segment display (DCM-SD), were implemented for monitor-based, AR-assisted wiring instruction on a formboard. The results reveal a substantial influence of the wire path visualization modes on task time under our controlled experimental conditions: the SCM group achieved an 18% shorter task time than the other two groups, with a statistically significant difference. This finding contradicts the existing observations in the mechanical assembly domain. For gaze behavior, an analysis of the eye-tracking data indicated that the number of switches in the SCM group was the lowest among the three groups, with a marginally significant difference from the DCM-FD group for both low- and high-complexity wiring tasks during the laying phase. Additionally, the total fixation time of the three groups showed a significant difference for low- and high-complexity tasks with a large effect size; the SCM group exhibited the shortest total fixation time across all tasks. No significant differences in the number of assembly errors and users’ perceived workload were observed among the three groups. These findings can serve as a reference for guiding the visual style design in AR-assisted wiring systems for training novice operators in human-centric Industry 5.0 and achieving a decrease in overall workload and improved task performance.