Assembling Components with Intelligent Tools

After raw material staging was successful, the production process automatically confirms the first operation (STAGING). As you can see in the following screenshot, it selected the right SFC in the POD and put it into the queue of the ASSEMBLY operation:

In the next step, the operator attaches the cap to the electronic part with three screws. The operator is guided to pick the correct screws from the correct box. In our example, the operator can take screws from three different boxes – however only one box contains screws in the correct size. A pick-by-light system indicates the correct box. For example, a red highlight on one box indicates an incorrect selection, while a blue light identifies the proper box.

To start this process, select the operation ASSEMBLY and choose Start:

In the background, SAP Digital Manufacturing validates that the user took the screws from the right box.

The following business benefits are shown in this process step:

• Increased Efficiency: The pick-by-light system streamlines the selection process, reducing the time taken to pick the correct screws.

• Error Reduction: The visual cues (red and blue lights) minimize errors by clearly indicating the correct box, preventing the use of incorrect screws.

• Improved Accuracy: By guiding the operator to the right box, the system ensures the accuracy of assembling the electronic component, reducing the chances of rework.

• Operator Training and Support: The guidance system aids operators in making accurate and efficient selections, thereby reducing training time and improving onboarding processes.

• Real-Time Feedback: The immediate validation and feedback mechanism enhances operational transparency and helps operators quickly correct errors.

• Safety Enhancement: Clear instructions and reduced manual decision-making might enhance workplace safety by minimizing errors and distractions.

The operator uses an intelligent screwdriver to tighten the screws. The system preloads the screwdriver with the required torque and angle specifications for the manufactured control head from set points defined in SAP Digital Manufacturing. The system guides the worker using projection instructions to ensure they assemble the screws in the correct positions with the correct force.

In the background, SAP Digital Manufacturing tracks each screw operation, including torques, angles, and execution quality. These details are stored for quality control and traceability. Additionally, the system unlocks the screwdriver only after the user starts the respective operation and locks the tool at the end of the assembly step.

The business benefits are as follows:

• Precision and Accuracy: The intelligent screwdriver ensures screws are tightened with exact torque and angle specifications, minimizing errors and ensuring consistent product quality.

• Guided Assembly: Projection instructions help workers assemble screws in the correct positions, reducing assembly mistakes and enhancing productivity.

• Quality Assurance: Tracking torque values, angles, and execution quality by SAP Digital Manufacturing allows for real-time monitoring and quality assurance.

• Traceability: Storing details of each screwing operation provides a clear record for traceability, aiding in compliance and product recalls if necessary.

• Operational Control: The system prevents unauthorized use by locking the screwdriver until the user initiates the appropriate operation, enhancing security and workflow integrity.

• Efficiency Enhancement: Automated tracking and guidance streamline the assembly process, reducing assembly time and labor costs.

• Improved Training Performance: Projection instructions serve as a training tool for new operators, helping them achieve high performance more quickly.