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The level of complexity in industrial manufacturing is increasing, driven by among other things shorter production cycles and greater product variances. Yet still, many processes at the assembly station are still being performed manually which increases the risk for human errors. So what to do? Well, why not empower your operators by error-proofing their station tasks so that they can do a better job?

 

 

There is a lot going on at an operator station

 

Human errors and associated quality issues caused by increased complexity are a major challenge at the operator assembly station. A challenge that is often addressed by engaging highly skilled and experienced operators. But despite this, mistakes do happen and with experienced operators becoming a scarce resource, the skills gap in manufacturing is growing.

 

But there are other ways to take control of complexity and turn it into a competitive advantage.

 

 

The augmented operator

Augmentation refers to the use of technology to empower and engage operators. To implement digital solutions working alongside operators to drive better manufacturing performance in a safer way with fewer errors, higher quality and throughput, faster changeovers and less downtime down

Take control of the assembly station operations, guide your operators to do the right thing in the right order and error-proof their performance. Let the empowerment begin!

 

 

 

 

Smart Integrated Assembly - Control challenges

Control

Operator user-friendly tool location systems ensure that assembly tools only operate if used in the correct area in the plant, for the right process, and on the right parts and products.

Smart Integrated Assembly - Guidance chain challenges

Guidance

Intuitive interfaces such as computer vision systems and error-proofing software, interact with the operator as they work and provide continuous guidance. This reduces the responsibility on the operator and helps them perform tasks in the correct order. Advantages that ease the need for extensive training and ultimately reduce costs for reworks.

Smart Integrated Assembly - Quality Assurance challenges

Quality assurance

Many errors are too difficult for humans to detect, and the processes are very complex. With error-proofing software and management system monitoring solutions you reduce the number of rework and the cost for expensive and continuous quality checks.

south america car manufacturer case

How to address expansion in a engine dress up assembly and operator guidance limitations, while keeping quality and profitability

A major car manufacturer in South America needed a new solution to improve their engine dress up assembly. A solution that would address expansion and operator guidance limitations in their current Programmable Logic Controller, PLC, system. The solution not only solved these issues, it enabled annual savings of over €1,000,000.

The Atlas Copco roadmap to smarter manufacturing

Smart Integrated Assembly is our concept for industrial manufacturers looking to transform and implement Smart Factories. It encompasses our ecosystem of tools, hardware, software and services solutions providing unrivalled competitive value in each step of the customers’ product manufacturing cycles. The result is more efficient, flexible, adaptable, and safe manufacturing processes that support reduced downtime, better use of materials and energy and a substantial waste reduction.

 

 

Station Controlled - our portfolio of products and solutions

Find the best tool for your specific needs and manufacturing conditions.

Socket selector
Selector 6
Socket selector
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Industrial Location tools
ILT Tool Tag ST61-S
Industrial Location tools
Power Focus 8
Power Focus 8 Thumbnail
Power Focus 8

Learn more and be inspired!

Let us share our knowledge and experience and leave the rest to your imagination.

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MWR 50 TA with ratchet application in motor tightening with operator hand
Extended connectivity for Dimensional Checks
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EV Battery Assembly: Battery Tray Assembly
ILS Tag
EV Battery Assembly: Battery Tray Assembly
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Optimized tightening processes go hand in hand with profitability and sustainability
Environmental risks in the supply chain
Optimized tightening processes go hand in hand with profitability and sustainability
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Top 5 mistake-proofing techniques in assembly
Solutions for error proofing
Top 5 mistake-proofing techniques in assembly
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To sum it all up

“Station Controlled” is the second of five steps in the Smart Integrated Assembly concept which starts with “Joint Fastened” and ends with “Station Automated”, Line Connected” and “Factory Integrated”.

A comprehensive Industry 4.0 offering that starts with that very first fastened joint and ends with a fully integrated Smart Factory. Manufacturing processes reengineered by Atlas Copco. Getting it right from the start.