While large series have long been produced automatically, meaning that hardly any human intervention is required, the situation is different for small series: As frequent product changes when using a machine are associated with high financial and time expenditure, manual manufacturing processes prove to be more cost-effective. In addition, many products are so complex that assembly can only be carried out by hand. This is also the case at Fluitronics, a Krefeld-based manufacturer of hydraulic components, where valve block assembly was previously carried out by hand over several stations - with the aid of assembly instructions on paper only, resulting in potential errors and long throughput times. In order to make the manufacturing process more efficient, Fluitronics was looking for an assistance system that was easy to install and could be easily adapted to the company's own requirements.

The Elam Start assistance system from Armbruster Engineering was chosen. Fluitronics can now use it to create step-by-step instructions for the assembly of different components itself in a short space of time. In this way, product changes can be carried out without wasting time. In addition, assembly is supported by a pick-to-light system, which reduces the error rate and shortens production time. Armbruster has designed the assistance system in such a way that it can also be used in different industries.

A system usually consists of the assistance software, a 2D scanner and pick-to-light shelf displays. A screwdriver and printer connection is also possible if required. Elam Start can be used for up to three networked manual workstations. © Armbruster Engineering

Create assembly instructions yourself
At Fluitronics, 45,000 control blocks in different sizes and more than 200 active variants are produced annually in the valve block assembly department, of which a good 40 versions are produced in large quantities and are suitable for line assembly. The company initially selected the Elam Start package for three manual workstations each for assembly and placement in the valve block area, as well as an assistance system in the packaging area. Before installation, Djordjevic and a colleague at Armbruster Engineering were trained on site to be able to set up the system themselves. All they had to do was assemble the screwdriver and PC suspensions as well as the holding devices. In addition to the hardware training, which included setting up the scanner and the pick-to-light compartment displays, the employees also received software training to prepare the assembly instructions for the assistance system. The software contains masks that guide them step by step through the creation of new assembly instructions; no special programming knowledge is required.

Assembly and material flow is supported
It took Fluitronics just two weeks from installation to commissioning. Assembly is now fully supported by Elam Start at three stations. It is also used to control the material flow of the parts to be assembled. Whereas previously every employee had to have extensive knowledge of the necessary components in order to ensure the smoothest possible assembly process, new employees can now be trained within five minutes - even without any prior knowledge of the individual components.

Digital, self-created work instructions are available for assembly and placement, which show the individual process steps and can be created within a very short time using software. For further support, after scanning, the worker is shown exactly in which compartment the required components are provided by means of images, text and the pick-to-light system - assembly errors, for example because the wrong part was installed, can be ruled out with great certainty in this way. The necessary instructions can be created within three to four days. The system ensures traceability and transparency. The employees at Fluitronics are impressed by the system and can now make adjustments independently. There are no more production downtimes. Even with constant changes in production - around 15 different products are now manufactured on the assembly line with the help of Elam - the transitions are almost seamless without long start-up times, according to Fluitronics. The next step for the company is to automate further processes. The Elam system's Web-IO module, which can be used to connect digital signals, will be integrated for this purpose. pb