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 digitalization and networking of production processes. However, the increasing complexity of technical solutions also places increased demands on employees in industrial and craft businesses. Thanks to new technologies, employees can interact and work together with machines in innovative ways.

Employee relief and reduction of errors

Modern assistance systems offer comprehensive support and relieve both cognitive and physical strain. The use of such systems can reduce error rates and workloads and increase employee satisfaction.

Support from assistance systems can be divided into three categories.

1. Increasing efficiency in the workplace by providing the assistance system with additional physical or mental support to the employee to complete tasks even more efficiently.
2. Promoting workplace ergonomics by making the work system easier for the employee and enabling tasks to be carried out safely and ergonomically.
3. Compensating for limitations by enabling older employees or employees with disabilities to be effectively integrated into the work environment thanks to 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 used in many assistance scenarios.

Classic worker assistance systems via screen, touchscreen or display

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 interact intuitively.

Different types of screens and touchscreens are used in modern manufacturing. These range from simple monitors to robust industrial touchscreens to high-quality HMI touchscreens. Choosing the right screen depends on the requirements of the respective application.

Interaction with screens via touchscreens is particularly common in production and assembly. Employees can perform actions, change parameters or retrieve information by simply touching the screen. This makes the operation of the 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 station.
  
• Complex, multi-variant end products can be easily assembled using clear, step-by-step assembly instructions. The integration of assembly videos makes it even easier to convey 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 workflows and to continuously improve processes in the spirit of a living quality management system (Plan - Do - Check - Act = PDCA cycle)
  
  
• Workflows of individual workstations can usually be selected using drag-and-drop on the touchscreen and moved if necessary. This enables optimal detailed planning and utilization of production capacities, as well as easy recording of actual times.
  
  
  
• Complete documentation of the manufacturing process for quality assurance 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. Work processes can be completed via machine signals (EOL test station).
  
  
• Display general company messages such as new hires, company events, successes, sales 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 the expensive HMI touchscreens from scratches and damage, it is recommended to use high-quality screen protectors or extremely robust hybrid glass . These protective films or hybrid glasses offer reliable protection against scratches, dirt and impacts. In addition, the matte and anti-reflective versions reduce annoying 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 work process is possible without fatigue.

Increased service life and employee satisfaction

The use of screen protectors or hybrid glass not only increases the service life of the devices, but also increases employee satisfaction. By protecting the screens, expensive repairs are avoided and downtime is minimized. Employees can therefore concentrate fully on their tasks without having to worry about the safety of the touchscreens.

In summary, it can be said that interaction usually takes place with the screens. Often via touchscreens, which enable intuitive operation. The use of screen protectors or hybrid glass offers effective protection against scratches and damage, increases the service life of the devices and increases employee satisfaction.

Virtual Reality Systems

VR systems (Virtual Reality) enable employees to immerse themselves in completely virtual worlds. This means that training can be carried out on non-existent equipment, for example, or dangerous situations can be simulated without risk. 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, expand the perception of the real world with additional information. They range from simple pick-by-light systems that guide employees to the parts they need 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 and machine and system statuses directly in the field of vision. They can also be used to guide the user to a specific location, for example in a warehouse.

Mixed Reality Systems

Finally, MR (Mixed Reality) combines both concepts and enables the creation of interactive virtual objects in the real world. Users can be, for example, 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 in a real location and their effects to be tested directly. This is particularly beneficial for workplace planning. Improved sensor technology is also making it easier to create location, To record shape or surface features in these areas and thus integrate documentation and quality control seamlessly 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 attached to the outside of the body and serve as support structures that mechanically support and reinforce the worker's movements. Exoskeletons can be divided into active and passive structures, depending on their components and functionalities. Active exoskeletons have mechanical elements and components that help reduce load and force. This is achieved, for example, by built-in electric motors and batteries.

What are passive exoskeletons?

Passive exoskeletons, on the other hand, support the body exclusively through mechanical components such as weights, springs or rails, without having an active drive. While passive exoskeletons are already used in the production of well-known companies, active exoskeletons are mostly still in the test phase. This is partly due to the significantly lower acquisition costs of passive exoskeletons, which are 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 charge the batteries, passive models do not depend on external power supplies. Active models are often heavier, but offer significantly greater support. With the help of such assistance systems, the biomechanical stress on employees can be reduced, which leads to a reduction in sickness-related absences.

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 highlighted how these systems increase productivity,improve employee satisfaction and include older or disabled workers. It examines different types of assistance systems, including cognitive systems such as augmented reality, virtual reality and mixed reality, as well as physical systems such as exoskeletons. It explains how these systems can assist employees in various tasks by providing visual instructions and multilingual information, facilitating assembly processes and integrating machine data. The blog post concludes by emphasizing 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.

Key findings

• Assistance systems in the fourth industrial revolution offer numerous benefits, 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 crafts.
• 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 expensive repairs.
• Physical assistance systems such as exoskeletons provide mechanical support for workers, reduce biomechanical stress and minimize sick leave.