Companies have to react quickly to changes in quantities, variants or the degree of automation. Even if the systems are ready for operation in a short space of time, the new procedures must first be implemented safely in the production process and employees must be retrained. It is not uncommon for assembly errors to occur - for example due to inadequate or misunderstood assembly instructions - or carelessness. Even if employees are already very experienced, changes in the workflow can easily be overlooked.

With its Operator Guidance software , Deprag is launching a solution to effectively prevent many defects in the production process. The software supports employees during assembly and prevents errors. Whereas previously every worker had to have extensive know-how in order to guarantee a smooth assembly process, complex processes can now be easily communicated. The app guides the worker step by step through the assembly process - even new employees without the relevant prior knowledge can be trained in a short time, according to the company.

Intuitive guidance - fast and reliable installation
The software enables the creation of any number of digital installation instructions. Operator Guidance is installed on suitable hardware with an operating system (Windows 7 or higher). The PowerPoint program and a display device at the manual workstation are also required. First, a work instruction with the individual assembly steps is created for each component using PowerPoint. The flexibility of PowerPoint opens up a wide range of visualization options - texts, images, videos or audio files can be easily integrated. "Our customers can configure any number of components and product groups themselves, without any programming knowledge," says Daniel Guttenberger, Product Manager for Deprag Schraubtechnik. There is no need for time-consuming coordination between the manufacturer and customer.

In the component configurator, the self-created work instructions are linked to the various screwdriving programs and rules - without a higher-level PLC. A separate screwdriving program is stored for each individual screwdriving point. As soon as the screwdriving point is reached in the process, the corresponding screwdriving program is activated in the sequence controller. The transmission between the screwdriving controller and the PC takes place via a direct cable connection or indirectly via the customer's normal Ethernet network. Automatic monitoring of each screwdriving point determines whether an OK or NOK result has been achieved. Depending on the screwdriving result and the configured rule, a different work step is displayed to the worker.

The combination with the Deprag position control stand (PKS), which is available as standard, creates even more process reliability. Position control systems coordinate and optimize the entire production process and ensure that the right fastener is tightened at the right time, in the right place and with the right torque. When screwing several screws to a component, the sequence in which the individual screws are tightened sometimes plays an important role in process reliability. Position control systems control this sequence: The screw can only be tightened if the worker has followed the correct sequence.

However, the software is not only suitable for simple user guidance and quick training of new employees, but also enables automatic process data documentation.

Automated archiving and documentation of process data
Seamless documentation of production data is becoming increasingly important. With Operator Guidance, the process data for each component can be stored and saved centrally: on a drive or in the cockpit. Manual collection of data is no longer necessary. The process data and screwdriving results are automatically linked to the serial number of the component. The screwdriving positions with the respective final values are saved for each serial number. This allows complete traceability and transparency.

The software also enables the integration of customer-specific extensions (so-called plug-ins). The customer can integrate their own processes and programs for defined events (component successfully screwed together, screw joint successfully screwed together). Communication with the customer-specific MES system, the transfer of final values, the display of further work instructions or similar are conceivable.

The software is particularly suitable for simple manual workstations without a PLC in order to increase process reliability. It can also be used at repair workstations. For example, the worker selects the screwdriving point to be repaired from a product image. The software automatically recognizes the correct screwdriving program. In addition to screw fastening, other assembly processes such as gluing or pressing are also possible.

If a customer wants to implement a new assembly process, all requirements must first be defined, such as the following: The correct screw sequence must be adhered to, different torques are required for the individual screw positions and, of course, it must be ensured that no screw is forgotten. At the same time, all process data such as torque, angle of rotation, status, screw position and serial number should be assigned to the respective component and saved automatically.

The customer uses Operator Guidance to create all work steps and the associated process parameters. Once configured, the software guides the operator step by step through the assembly process. At the manual workstation, all instructions are clearly shown to the operator on a screen. The operator must first scan or manually enter the serial number of the component to be processed in order to link the process data to the component from the outset. Depending on the component, the software immediately and automatically provides the corresponding digital work instructions and shows the worker the next assembly step. For further support, the employee is shown exactly which compartment the required components are to be taken from by means of images, text or short videos.

It then screws each screw position according to a predefined sequence. It automatically monitors whether there is an OK or NOK result. Depending on the screwdriving result and the configured rule, the next work step is displayed to the worker. As soon as individual work steps are inadvertently not carried out or carried out incorrectly, the system blocks new work steps until the previous ones have been carried out correctly. as