Digital unloading assistant

RK Metalltechnik is a versatile contract manufacturer specialising in sheet metal processing. They offer customised solutions for small batch sizes with a delivery time of just 5 working days. Services include laser cutting, edge rounding, bending, welding and mechanical processing. When unloading the laser cutting system, employees have to clear parts quickly. In order to further improve competitiveness and further reduce delivery times, the aim of the project is to determine whether a spatial augmented reality system can support this.  Specifically, it is about the technical feasibility of an active visualisation for a better understanding for the machine operator through projection directly on the sheet metal parts including the necessary interfaces in the digital process chain. This involves assessing the technical feasibility of an active visualisation system that projects information directly onto the sheet metal parts, aiding machine operators in better understanding and quickly managing the unloading process.

The solution deals with the integration of active projection technology based on a multi-projector setup in manufacturing to enhance the efficiency of unloading and order picking from the cutting table. This innovative solution ensures parts are directly loaded into customer containers with greater accuracy and speed.

Key aspects of the solution include:

• Active Visualisation: Utilising projection technology, colored highlights and essential information are displayed on the cutting table, guiding operators on part selection and sequence. 

• Technical Feasibility: A detailed analysis confirmed the technology's integration with existing machinery and its capability to accurately project necessary information. 

• Digital Integration: Adjustments in the digital process chain were made to ensure the projection system received order data, enabling dynamic operator guidance.

• Laboratory Demonstrator: A proof of concept was developed in a controlled environment, testing the system's practicality and effectiveness.

• System Integration Evaluation: The concept's compatibility with existing systems was thoroughly assessed, ensuring seamless operational enhancement.

This implementation significantly improves parts handling efficiency and accuracy, showcasing the effective combination of traditional manufacturing processes with advanced digital technologies for optimised performance.  By leveraging multi-projector setups and real-time guidance systems, this solution enhances operator productivity and minimises errors during the unloading and order picking process. This transformative solution not only streamlines operations but also showcases the potential of innovation to drive tangible benefits in productivity, quality, and customer satisfaction within the manufacturing industry.

• Digital Interface Enhancement: The projection system acted as a digital interface between human operators and machinery, effectively expanding the existing CAD/CAM process chain. This integration facilitated faster order picking, contributing to a noticeable reduction in delivery times.

• Workload Reduction for Employees: By providing a clear, visual guide for part selection and placement, the system significantly reduced the cognitive and physical workload on employees. This led to a more streamlined and less error-prone process.

• Elimination of Paper-Driven Processes: The projection technology eliminated the need for paper-based processes and reliance on fixed displays. Operators received real-time, projected information directly on the components, detailing clearing orders and the necessary picking process for each order.

• Equipment and Development Scope Derivation: The project successfully outlined the necessary scope of equipment (both hardware and software) and the developmental efforts required for a pilot system in a real-world environment.

Through these advancements, the projection system not only improved operational efficiency but also enhanced the working conditions for operators, marking a significant step forward in integrating digital solutions into traditional manufacturing settings.

• Importance of User-Centric Design: Tailoring technology to meet operator needs is crucial for successful integration and adoption.

• Seamless Integration is Key: Harmonising new technology with existing processes ensures minimal disruption and maximises efficiency gains.

• Continuous Feedback Loop: Regular input from end-users, like machine operators, is essential for refining technology applications in real-world settings.

• Evaluating the projection system at the target facility is a valuable approach, as it allows for real-time assessment and adjustment in the actual working environment, ensuring the technology meets specific operational needs effectively.