Avantguard: Error-Proofing for the Industry 4.0 Era

Building a smarter production line begins with Avantguard. The manufacturing landscape is always evolving, and we must adapt to these changes to remain profitable and competitive. Explore how software can revolutionize your assembly, enabling you to trust your tools and operators to perform at their best.

Since the first industrial revolution, the operator has been imperative to the manufacturing experience. There’s a reason why, even today, we rely heavily on our operators to complete assembly tasks. Humans are easily adaptable and flexible, have critical thinking and problem-solving skills, have situational awareness, are innovative and bring to light new ideas, and, of course, pair perfectly with the automated technologies of today. Without the human operator, we could not produce today's innovative technologies.

However, it is also realistic to accept the human operator's downfalls, including fatigue, inconsistent operating, miscommunication/misunderstanding, and more. Thankfully, the latest technology of Industry 4.0, such as automated technology, is ready to help improve the operator experience.

Alas, automation isn’t without its faults. Ironically, all the key aspects that make the human operator a vital asset are also the same factors that automation lacks. Without critical thinking skills and situational awareness, automated technology can unintentionally repeat the same mistakes over and over again if left unchecked. Additionally, much like the way humans get sick, automated technology can unexpectedly fail, resulting in unexpected downtime and other consequences to your assembly. In this way, both the operator and the machine mutually benefit from each other. While the robot manages repetitive tasks that would typically bore operators, humans can concentrate on more complex aspects of the application that automation cannot tackle or even take over the application when automation falls short.

While each side can help error-proof the other, the era of Industry 4.0 has introduced more software solutions that can further error-proof assembly and virtually eliminate them through advanced monitoring capabilities. Avantguard is one such solution, enabling you to further optimize assembly while placing trust in both your operators and automated solutions. Read on to explore this innovative technology and determine if it’s right for your assembly.

Avantguard is the ultimate solution for error-proofing manufacturing operations. It ensures efficiency and exceptional product quality by improving the assembly process for all product variants, identifying errors, and assisting operators with complex tasks and repairs, enabling your manufacturing facility to prosper. In this article, we will examine how Avantguard collaborates with your existing line to eliminate errors for both your operators and your machines. Let’s first begin by exploring how Avantguard helps guide operators and ensures full traceability of the assembly application. Read on to learn more.

When monitoring your operators during production, this software solution ensures consistency in three main ways: through step-by-step operator guidance, guided rework and repairs, and, finally, user authorizations. Without any further delay, let’s dive into this exciting solution!

Operator guidance is a great tool for protecting your products from common errors that occur during assembly. When operators accidentally use the wrong tool or apply the wrong torque, your production can suffer, leading to frequent rework and repairs. To avoid this, Avantguard is developed to guide your assembly, providing comprehensive, step-by-step operator guidance and real-time feedback, ensuring everything is made according to the proper specifications. This enhances your assembly efficiency and supports production accuracy, enabling you to stay productive and profitable.

To further safeguard your assembly, Avantguard is equipped with tool interlock and part verification capabilities. In addition to the step-by-step operator guidance, Avantguard will ensure that your tools are activated at the right time and with the correct tightening program. Operators can use them only when needed and with the correct task parameters, reducing downtime, possible damage to the product, and potential negative effects on your profits.

In the event that errors occur, Avantguard will stick by your operator’s side, guiding them through the entire rework and repair process. This will enable operators to effectively address issues with clear instructions and support, minimizing downtime. With Avantguard, you can complete your rework and repairs faster than before, allowing you to get back to business as usual.

At Atlas Copco, we understand how crucial security is to your entire operation. Without the right measures, anyone could tamper with your specifications, leading to mis-torqued joints and other errors on the line if not properly managed. That’s why Avantguard incorporates user authorization features, allowing for access control and ensuring that only authorized personnel can operate specific functions, thereby enhancing security and accountability.

Error-proofing your automated technology is just as critical as error-proofing operators. While automation completes dependable and consistent tightening, that same trait that makes it accurate and fast can also lead to your solutions making repeatable mistakes during production. When your automation unexpectedly fails, it is essential to keep stations productive by allowing operators to step in and take over without sacrificing quality or traceability. That’s where Avantguard comes in.

If unexpected downtime occurs, you can still safeguard your quality standards and maintain output by utilizing Avantguard as a backup station. It allows operators to seamlessly continue assembly operations even when robotic systems are down. With detailed operator instructions and the same level of quality assurance as automated processes, including data collection and process compliance, your operators will be equipped to manage the tasks and maintain production flow.

Firstly, Avantguard is a web-based application that allows worldwide accessibility across devices, facilitating seamless data access and collaboration. With this feature, authorized users can swiftly make changes to the production process without any coding requirements, thereby enhancing operational flexibility and efficiency.

Finally, Avantguard seamlessly integrates with a variety of devices and machines, including third-party options, providing flexibility and connectivity. This allows for interoperability and data exchange between manufacturing systems (MES/PLC), resulting in streamlined operations and improved control. In this way, Avantguard adapts to the assembly process and guides the operators according to the requirements of the product variants, ensuring reliable, accurate assembly.

Today, it is more important than ever to maintain consistent assembly. With it, you can achieve seamless assembly, high production quality, and increased profits. While many solutions are gaining traction that can help you achieve such goals, more can be done to keep everything on track. Smart software solutions are the future of manufacturing, enabling you to understand your line better and keep track of every aspect.

Avantguard is a solution that monitors your line and keeps both your operators and machines on track. With this solution integrated into your assembly, you can ensure that everything runs as expected. To learn more about Avantguard or to request a product demonstration, contact the experts at Atlas Copco.

To learn more about how Avantguard can revolutionize your assembly, watch our on-demand webinar to explore the future of error-proofing in the era of Industry 4.0.