What are worker assistance systems? Worker assistance systems enable a relief of employees in production and on the...
Worker assistance systems for assembly and production
What are digital worker assistance systems?
The currently much-discussed Fourth Industrial Revolution, also known as Industry 4.0, offers new opportunities to increase productivity and flexibility through the digitization and networking of production processes. However, the increasing complexity of technical solutions also places higher demands on employees in industrial and craft businesses. Thanks to new technologies, employees can interact and collaborate with machines in innovative ways.
Employee relief and error reduction
Modern assistance systems offer comprehensive support and relieve both cognitively and physically. By using such systems, error rates and workloads can be reduced, and employee satisfaction can be increased.
Support through assistance systems can be divided into three categories.
- Increasing efficiency in the workplace by providing additional physical or mental support to employees through the assistance system to complete tasks even more efficiently.
- Promotion of workplace ergonomics by making work easier for employees and enabling a safe and ergonomic execution of tasks through the work system.
- Compensation for limitations by effectively integrating older employees or employees with disabilities into the work environment through the use of technical aids and assistance systems.
Cognitive Assistance Systems
Cognitive assistance systems include modern technologies such as Augmented Reality (AR), Virtual Reality (VR), and Mixed Reality (MR). These flexible technologies are already being used in many assistance scenarios today.
Classic worker assistance systems via screen, touchscreen or display
Input: Worker assistance systems are playing an increasingly important role in production, assembly, and manufacturing. These intelligent systems support employees in their daily work and help to increase the efficiency and quality of production. A central component of these systems are the screens and touchscreens, which enable employees to have an intuitive interaction.
In modern manufacturing, various types of screens and touchscreens are used. These range from simple monitors to rugged industrial touchscreens to high-quality HMI touchscreens. The choice of the right screen depends on the requirements of the specific application.
Especially in production and assembly, interaction with screens via touchscreens is very common. Employees can perform actions, change parameters, or retrieve information by simply touching the screen. This makes the operation of worker assistance systems extremely user-friendly and intuitive.
What content can assistance systems display?
- Drawings, material lists, work and test plans as well as general information such as canteen plans or accident prevention regulations (UVV) and many other PDF documents are displayed in multiple languages directly at the assembly site.
- Complex, variant-rich end products can be easily assembled using clear step-by-step assembly instructions. The integration of assembly videos further facilitates the transfer of knowledge and information.
- Graphic editors with various graphic widgets such as images, videos, checklists, PDF displays, text blocks, and much more are used to provide feedback on work processes and continuously improve processes in the context of a dynamic quality management system (Plan - Do - Check - Act = PDCA cycle).
- Workflows of individual workstations can usually be selected and moved via drag-and-drop on the touchscreen. Optimal detailed planning and utilization of manufacturing capacities, as well as easy recording of actual times, are enabled.
- Seamless documentation of the manufacturing process for quality evidence and as a basis for production improvements. ISO 9001 and IATF16949 compliant.
- Integration of test and machine data interfaces into the machine environment to integrate test and machine data into the digital assistance solution. Workflows can be completed via machine signals (EOL test station).
- Display general company news, such as new hires, company events, successes, revenue figures, and the status of all workstations at the individual assembly stations. Direct immediate integration into the shop floor management system.
Protection of expensive displays, screens, and touchscreens
To protect expensive HMI touchscreens from scratches and damage, it is recommended to use high-quality display protection films or extremely robust hybrid glass. These protective films or hybrid glasses provide reliable protection against scratches, dirt, and impacts. In addition, the matte and anti-reflective versions reduce distracting reflections on the displays, which is particularly advantageous in bright ambient light. The workers' eyes no longer tire, and reading important information for the next assembly step or task is fatigue-free.
Increase in lifespan and employee satisfaction
The use of screen protectors or hybrid glass not only increases the lifespan of devices but also enhances employee satisfaction. By protecting the screens, expensive repairs are avoided and downtime is minimized. Employees can therefore fully focus on their tasks without having to worry about the safety of the touchscreens.
In summary, it can be said that interaction typically takes place with screens, often through touchscreens that allow for intuitive operation. The use of screen protectors or hybrid glass provides effective protection against scratches and damage, increases the lifespan of devices, and enhances employee satisfaction.
Virtual Reality Systems
VR systems (Virtual Reality) enable employees to immerse themselves in completely virtual worlds. This allows, for example, training to be conducted on non-existent devices or dangerous situations to be simulated risk-free. Such systems have been an integral part of pilot training in flight simulators for many years.
Augmented Reality Systems
AR systems (Augmented Reality), on the other hand, enhance the perception of the real world by providing additional information. They range from simple Pick-by-Light systems that guide employees to the required parts during assembly, to digital projection systems that dynamically project assembly instructions onto work surfaces, or mobile data glasses that can display useful information such as part numbers, machine and equipment statuses directly in the field of view. They can also be used to guide the user to a specific location, for example in a warehouse.
MR-Systems
Finally, MR combines both concepts and enables the creation of interactive virtual objects in the real world. Users can, for example, be maintenance technicians who have a 3D model of the machine to be repaired available on site, or installers who can directly display or overlay the planned position of the parts to be installed. MR is also used in the planning and design phase, as it allows virtual objects to be inserted at a real location and their effects to be tested directly. This is particularly beneficial for workplace planning. With improved sensor technology, it is also becoming increasingly easier to capture location, shape, or surface features in these areas, thus seamlessly integrating documentation and quality control into the workflow.
Physical Assistance Systems
What are active exoskeletons?
An alternative form of support is provided by physical assistance systems, such as exoskeletons. These assistance systems are increasingly being used in industrial and logistics companies. They are externally attached to the body and serve as support structures that mechanically assist and enhance the movements of the worker. Exoskeletons can be divided into active and passive structures, depending on their components and functionalities. Active exoskeletons have mechanical elements and components that contribute to load and force reduction. This is achieved, for example, through built-in electric motors and batteries.
What are active exoskeletons?
Passive exoskeletons, on the other hand, support the body solely through mechanical components such as weights, springs, or braces, without having an active drive. While passive exoskeletons are already being used in production by well-known companies, active exoskeletons are mostly still in the testing phase. This is partly due to the significantly lower acquisition costs of passive exoskeletons, which amount to only a few thousand euros.
Conclusion Exoskeletons
Both active and passive support structures have advantages and disadvantages. While active exoskeletons rely on external power sources to recharge the batteries, passive models do not depend on external power supply. Active models are often heavier, but offer significantly higher support. With the help of such assistance systems, biomechanical strains on employees can be reduced, leading to a decrease in illness-related absenteeism.
Summary Digital Assistance Systems
The advantages of assistance systems in the context of the Fourth Industrial Revolution, also known as Industry 4.0, are highlighted. It is explained and emphasized how these systems can increase productivity, improve employee satisfaction, and include older or disabled workers. Various types of assistance systems are examined, including cognitive systems such as augmented reality, virtual reality, and mixed reality, as well as physical systems like exoskeletons. It is explained how these systems can support employees in various tasks by providing visual instructions and multilingual information, facilitating assembly processes, and integrating machine data. The blog post concludes with an emphasis on the importance of protecting expensive displays and touchscreens with high-quality protective films or hybrid glass, which not only extend their lifespan but also increase employee satisfaction.
Resultats and final thoughts
- Assistance systems in the fourth industrial revolution offer numerous advantages, including increased efficiency, improved ergonomics, and the inclusion of older or disabled workers.
- Cognitive assistance systems such as augmented reality, virtual reality, and mixed reality enable innovative interactions with machines and facilitate various tasks in industry and craftsmanship.
- Digital assistance systems can display a variety of content, including drawings, material lists, work plans, and general information to support employees in their daily work.
- Protective films or hybrid glass can protect expensive displays and touchscreens, extend their lifespan, and reduce the need for costly repairs.
- Physical assistance systems such as exoskeletons provide mechanical support for workers, reduce biomechanical stress, and minimize sick leave.
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