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Summary: In manufacturing, precise workflows and error-free assembly are crucial for quality and efficiency. Digital worker assistance systems (WAS) offer workers an innovative solution for achieving these goals. They guide employees step by step through complex production processes to ensure that assembly is carried out without errors. But how exactly do these systems help to increase efficiency in manufacturing while guaranteeing quality?
What exactly is a worker assistance system?
A worker assistance system (WAS) is a digital solution that supports workers in their tasks. It provides all the relevant information needed to perform a work step in real time. This includes step-by-step instructions, design drawings, parts lists and inspection instructions. It also enables the entire process to be documented, ensuring complete traceability and contributing to a more efficient inspection process. Compared to traditional methods, such as the use of Excel lists or paper documents, a digital worker assistance system offers greater flexibility and up-to-date information. It can be used on various devices such as tablets, smartphones or stationary screens and can be integrated into existing systems such as ERP or MES.
How can worker guidance and process safety be seamlessly combined?
flowdit makes complex workflows easy to manage – digital, clear, and ready to use instantly.
Advantages of worker assistance systems in assembly
Worker assistance systems are particularly advantageous in assembly. They offer many benefits that improve the entire assembly process:
Increased precision and fewer errors
Digital support significantly reduces errors. Clear instructions that include visual aids and step-by-step guides reduce the risk of assembly errors. This precision not only leads to higher-quality end products, but also prevents misunderstandings and errors resulting from unclear communication.
Faster training of new employees
An additional advantage is the rapid training of new employees. Digital support enables new employees to quickly familiarise themselves with assembly processes. All important information is immediately available, making it easier to learn the procedures. The effort required for training is reduced and the productivity of new employees increases.
Increased productivity
The clear structuring of work steps helps to minimise sources of error and avoid unnecessary tasks. This increases productivity and reduces the time required for the assembly process without compromising quality.
Better documentation and traceability
Worker assistance systems ensure that all work steps are recorded and documented in real time. This enables complete traceability, which is particularly important for quality controls and audits. The rapid availability of all relevant information makes it easy to comply with compliance requirements and quality standards.
How does a worker assistance system work?
A worker assistance system is software that runs on mobile devices, tablets or AR glasses and is directly linked to the assembly process. It provides workers with the information they need in real time to carry out work steps accurately and efficiently. The systems offer numerous functions that actively support workers and improve production quality:
- Structured work instructions: Clear, step-by-step instructions with visual aids ensure smooth workflows and prevent errors.
- Centralised access to information: The provision of production plans, design drawings and other relevant data in real time guarantees informed decision-making.
- Real-time error detection: Errors are immediately detected by the system and feedback is provided for correction before they affect the production process.
- Automated data collection: Important process data such as production times and quality indicators are automatically collected and made available for analysis.
- Automatic report generation: The system creates logs during the process to ensure documentation and traceability of production.
- Optimised communication: Feedback tools promote direct communication within the team and enable problems to be solved quickly.
Practical applications
Worker assistance systems are used in various areas of production, including:
- Assembly: Assistance with the error-free assembly of parts and components through digital instructions and real-time checks.
- Quality assurance: Ensuring compliance with quality standards through immediate detection and correction of deviations.
- Maintenance: Providing accurate maintenance and repair instructions that eliminate errors and reduce downtime.
- Logistics: Increasing efficiency by optimising picking and packing processes.
How significant are the realistic effects of using worker assistance systems?
The use of worker assistance systems can reduce errors by up to 51% and working hours by 20-30%. Studies also show a productivity increase of up to 69%, particularly in areas such as assembly and maintenance. Real-time error prevention and standardised workflows are crucial for these effects. These figures are based on practical studies and real-world applications in industry.Âą
Ollerer, M., Journal of Manufacturing Science and Engineering (2021).
Error-free assembly through digital worker guidance: your next steps
Error-free assembly is the cornerstone of successful manufacturing. This requires precise processes, clear communication and employee support. Digital worker guidance makes it possible to meet these requirements. It provides accurate, easy-to-understand instructions and eliminates sources of error directly in the process.
This is exactly where flowdit comes in. Our Connected Worker software provides employees with all the necessary information in real time, ensuring error-free execution. The solution can be easily integrated into existing production systems and can be adapted to the specific requirements of your manufacturing process.
With flowdit, you can optimise the performance and quality of your assembly processes. Errors are detected early, corrective measures are initiated immediately, and collaboration between teams at all levels is improved.
Take the opportunity to book a personalised demo and find out how flowdit can permanently optimise your manufacturing.
FAQ | Worker Assistence System
What exactly is a worker assistance system?
A worker assistance system is a digital platform that supports production teams in real time with precise instructions and decision support. It integrates seamlessly into existing systems and guarantees workflow optimisation by automatically providing context-specific information. By ensuring that all employees work in the same way, the system increases productivity and quality. It contributes to transparency and continuous optimisation in production by connecting machines, personnel and sensors with each other.
What is the difference between digital worker guidance and digital worker assistance?
Digital worker guidance provides employees with step-by-step instructions that they must follow in the specified order. Software ensures that tasks are completed in a structured manner and without deviation.
Digital worker assistance uses real-time monitoring and machine learning to continuously check work progress. It immediately detects errors or deviations and suggests corrective measures in real time to adjust the work process and increase efficiency.
How can a worker assistance system improve workflow in a manual production line?
- Real-time support: Digital instructions and feedback minimise errors.
- Error reduction: Ensures correct workflows and reduces deviations.
- Faster training: New employees are trained efficiently.
- Increased productivity: Reduces interruptions and optimises the process.
- Continuous improvement: Real-time data enables dynamic process adjustments.
- Traceability: Facilitates audits and quality controls.
- Knowledge transfer: Minimises knowledge loss when staff changes occur.
How can digital worker assistance be connected to existing systems such as ERP, MES or audit/checklist software?x
Digital worker assistance can be seamlessly integrated with ERP, MES and audit/checklist software via open interfaces (APIs). These interfaces enable the real-time exchange of relevant data such as production orders, machine status and test reports, which increases the efficiency and accuracy of work processes.
In which areas of production is digital worker assistance particularly worthwhile?
Digital worker assistance systems offer particularly great advantages in areas with complex, repetitive tasks and a high susceptibility to errors, such as assembly, inspection and maintenance. They provide clear, step-by-step instructions that support workers in each individual process. This minimises errors and increases efficiency. In maintenance, they help with the precise implementation of maintenance plans and the rapid identification of problems. Especially in complex repairs or tests, systematic instructions help to avoid errors and reduce knowledge loss when personnel changes occur.
How does digital worker guidance change the role of employees?
The introduction of digital worker guidance systems is transforming the tasks performed by employees: they are acting less as executors and more as active co-designers of the production process. The real-time information provided by the system enables them to contribute directly to quality assurance and process optimisation. They are increasingly responsible for ensuring compliance with standards and preventing errors.
What obstacles arise when introducing digital worker assistance?
- Integration: Difficulties connecting to existing systems (ERP, MES).
- Acceptance: Resistance from employees due to lack of training and involvement.
- Change management: Insufficient support and leadership during the transition.
- Adaptability: Software does not offer the necessary flexibility for specific processes.
Which technologies such as IoT, augmented reality or wearables are used in digital worker assistance systems?
Digital worker assistance systems use IoT sensors for real-time monitoring of machines and systems, AR for the visual display of instructions, and wearables such as smart glasses or wristbands that enable access to information and feedback directly at the workplace. These technologies ensure that employees have relevant data at their fingertips at all times and can respond immediately to problems.
Which key figures are crucial for measuring the success of a worker assistance system?
- Error rate: Reduction of errors in the production process through real-time feedback and precise instructions.
- Throughput time: Reduction of the time required to perform individual work steps or tasks.
- Training duration: Time savings in training new employees through clear, digitised work instructions.
- Productivity: Increase overall productivity through more efficient and standardised work processes.
- Employee satisfaction: Improve employee satisfaction and motivation through ease of use and support in everyday work.
- Compliance and safety: Compliance with safety guidelines and reduction of safety-related incidents.
How does a worker assistance system contribute to improving occupational safety?
A worker assistance system ensures compliance with specified safety requirements in all work processes, thereby contributing to operational safety. It monitors work progress in real time and alerts employees to potential hazards or deviations from safety standards. It also documents all safety-related steps, which improves traceability and compliance during audits.
What technical requirements are necessary for a digital worker assistance solution?
Mobile devices such as tablets or wearables connected to Wi-Fi or 5G are usually required to use a digital worker assistance solution.
In order to integrate current data such as production orders or machine status, the software must be able to communicate with ERP or MES systems in real time. Furthermore, the solution should have an easy-to-understand user interface and be compatible with the existing IT infrastructure.
