Smart interfaces application supporting employees on an assembly line at VOITH Turbo

How can “Industry 4.0” technologies be used in assembly so that the valuable knowledge of experienced employees is optimally available for the work process? And how to support employees at all ages, qualification, language skills,…, optimally by the use of dynamic systems at production lines? How to achieve higher productivity and improved harmonization of work content (“flow”)?

The research project of VOITH Turbo, TU München and STREMLER, "Smart interface-controlled jumpers support by employees with “modified performance” in assembly" has addressed these issues by developing an application for smart devices for improved communication and interaction. As a result, the working conditions are improved and the production capacity increased at the same time.

In general, the customization of the production of ultra modern and low-wear braking systems based on customer requirements requires a high degree of flexibility with regard to the creation of variants and changes during the production process.

The challenges of on-time-delivery and high quality standards often push employees to their limits. Help-giving jumpers, modern communication tools and digital planning and optimization systems in assembly help to avoid errors and productivity losses despite the high time and cost pressure.

The implementation of the project at Voith Turbo brought the following results:

• Simple simulation of new processes of a very complex one assembly with variable cycle times

• 15% increase in production

• 20% faster response time to problems

• Optimized use of personnel

• Maintaining the skills of “performance-modified” employees

As technology partner, STREMLER contributed to the research project with the simulation-based real time planning and control system, the basis for dynamic determination of efficient employee allocation and optimal deployment of jumpers.