How to reduce the share of faulty products on the factory assembly line?

We developed the software with augmented reality elements to facilitate the assembly of spar frames at the automobile plant helping to reduce the share of faulty products. We took into account all requests of the customer.

About the customer:

One of Europe's leading light commercial vehicles manufacturer.

Goals and objectives: maximum reduction of the defect rate

The customer turned to us to help reduce the number of defects on the assembly line: employees mixing up crossbars, brackets or inserting parts incorrectly into the frame. In a best-case scenario, they have to stop the conveyor to correct the mistakes at the quality control stage. In the worst scenario, the entire frame is rejected. The situation is explained by the assembly line employees having to assemble more than eighty frame modifications, so it is really easy to mix them up if you are a living person. Unfortunately, however, faulty components increase the cost of production than reduce the profits of the company. The following objectives were set in cooperation with the customer:

We had to find out how to provide to assembly workers relevant instructions because the conveyor should always work.

The solution: a digital assistant comes to the rescue

We conducted an audit of production and found that the main cause of the high share of faulty products was that it was difficult for workers to remember all the features of a large number of product modifications. As a result, we concluded that the best option would be to create an assistant with augmented reality elements.

  • We tested several variants and chose the best for the required functionality.

  • We developed the digital assistant for the augmented reality glasses.

  • We chose the lightest model of glasses to let workers feel comfortable during the day.

The AR program shows the employee detailed instructions on how to assemble exactly the frame that is in front of him now - it is simply impossible to make a mistake and mix up the parts.

Detailed instructions before engineer's eyes

When the engineer puts on the glasses, the simulator starts giving him step-by-step instructions and hints, such as which crossbar to take, to which hole to attach and which rivets to use.

The assembler sees the recommendations for a specific modification. No unnecessary information distracts the engineer.

Chose lightweight AR-glasses for employee comfort

To prevent AR glasses from becoming a nuisance and tiring during a work shift, we chose a lightweight and ergonomic model. Such products allow the engineer to move freely if necessary.

However, we can implement the same solution for any popular AR glasses.

A bit about technologies

For this project, we chose Unity as a 3D engine for modeling scenes. This tool allows building applications for Android, iOS, or Windows platforms at a fair price. As a recognition module, we used the Vuforia library, which offers advanced solutions for augmented reality content.
The main language of the project is C#.

The production platform is Windows 10, but the solution is cross-platform and can be quickly deployed for on, e.g., a microcomputer with Android.

Effective, personalized, innovative

We invite you to solve your challenge together

If you need a service with augmented reality features or another high-tech solution, don't hesitate to contact us to discuss how modern solutions can help your business.

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