What advantages do assistance systems offer?

The Fourth Industrial Revolution, also known as Industry 4.0, is currently a much-discussed topic. The digitalization and networking of production processes open up new possibilities for increasing productivity and flexibility. With the increasing complexity of technical solutions, the demands on employees in industrial and craft enterprises are also rising. New technologies enable employees to interact and collaborate with machines in innovative ways. Modern assistance systems offer diverse support and alleviate both cognitive and physical burdens. Through these systems, error rates and workloads can be reduced, and employee satisfaction can be improved. The support provided by assistance systems can be divided into three categories.

1. Increasing efficiency in the workplace: The employee receives additional physical or mental support from the assistance system to complete tasks even more efficiently.
2. Promotion of Workplace Ergonomics: The work system facilitates the work for the employee and enables a safe and ergonomic execution of tasks.
3. Compensation for Limitations: Older employees or employees with disabilities can be effectively integrated 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

Worker assistance systems play 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 intuitive interaction for the employees.

Worker assistance system on an assembly line

In modern manufacturing, various types of screens and touchscreens are used. These range from simple monitors to robust industrial touchscreens and 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 simply by touching the screen. This makes the operation of worker assistance systems extremely user-friendly and intuitive.

What content can assistance systems display?

Apart from typical text-based instructions, today visually processed information transfer plays a significant role. Just think about language barriers that can easily be overcome with the help of simple pictograms. Some more examples of the use of digital assistance systems:

• Drawings, material lists, work and inspection plans, as well as general information such as cafeteria plans or accident prevention regulations (UVV) and many other PDF documents are displayed directly at the assembly site in multiple languages.
• Complex, varied end products can be conveniently assembled using clear, step-by-step assembly instructions. The inclusion of assembly videos further facilitates the transmission 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 workflows and to continuously improve processes in the sense of a living quality management system (Plan – Do – Check – Act = PDCA cycle).
• Workflows of individual workstations can usually be selected via drag-and-drop on the touchscreen and moved if necessary. Optimal detailed planning and utilization of production capacities, as well as the easy recording of actual times, are made possible.
• Complete documentation of the manufacturing process for quality assurance and as a basis for production improvements. ISO 9001 and IATF16949 standard compliant.
• Integration of test and machine data Integrate interfaces into the machine environment to incorporate test and machine data into the digital assistance solution. Workflows can be completed via machine signals, such as quality inspections during final assemblies.
• Display general company announcements, such as new hires, company events, achievements, 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 advisable to use high-quality display protection films or extremely durable hybrid glass. These protective films, or hybrid glasses, offer reliable protection against scratches, dirt, and impacts. Additionally, the matte and anti-reflective variants reduce annoying reflections on the displays, which is especially beneficial 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.

Increase in lifespan and employee satisfaction

The use of screen protectors or hybrid glass not only increases the lifespan of the devices but also enhances employee satisfaction. By protecting the screens, expensive repairs are avoided and downtime is minimized. Employees can thus fully concentrate on their tasks without worrying about the safety of the touchscreens. In summary, interaction generally occurs with the screens, often via touchscreens that allow intuitive operation. The use of screen protectors or hybrid glass provides effective protection against scratches and damage, increases the lifespan of the devices, and boosts employee satisfaction.

VR systems

VR systems (Virtual Reality) allow employees to immerse themselves in completely virtual worlds. This makes it possible, for example, to conduct training on non-existent equipment or to simulate dangerous situations without risk. Such systems have been an integral part of pilot training in flight simulators for many years.

AR systems

AR systems (Augmented Reality), on the other hand, enhance the perception of the real world with additional information. They range from simple pick-by-light systems that guide employees to the necessary 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 (Mixed Reality) unites 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 into a real location and their impact to be tested directly. This is particularly advantageous for workplace planning. With improved sensor technology, it is also becoming increasingly easy to capture location, shape, or surface features in these areas, thus seamlessly integrating documentation and quality control into the workflow.

Physical assistance systems

Active exoskeletons

An alternative form of support is offered 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 amplify 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 contribute to load and force reduction. This is achieved, for example, through built-in electric motors and batteries.

Passive exoskeleton

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 used in the production of 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.

Summary of 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 supply. Active models are often heavier, but they offer significantly higher support. With the help of such assistance systems, the biomechanical stress on employees can be reduced, leading to a decrease in sick leave.

Summary of Digital Assistance Systems

The advantages of assistance systems in connection with 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 like 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 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.

Important insights

1. Assistance systems in the fourth industrial revolution offer numerous advantages, including increased efficiency, improved ergonomics, and the inclusion of older or disabled workers.
2. 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.
3. 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.
4. Protective films or hybrid glass can protect expensive screens and touchscreens, extend their lifespan, and reduce the need for costly repairs.
5. Physical assistance systems like exoskeletons provide mechanical support for workers, reduce biomechanical stress, and minimize sick leave.