L-mobile Digital Assembly Instruction System | Digital Work Instructions in Assembly

The L-mobile digital assembly instruction system facilitates automated working methods in your manufacturing and, as a digital worker guidance system, it always provides the right information regarding the manufacturing process. With the aid of auto ID technologies, such as RFID or UWB, orders are clearly identified and the appropriate work instructions and documents are displayed for each step of the manufacturing process. So even complex and variable assembly processes can be implemented in a short space of time and without lengthy training. Produce smaller quantities in succession, without reorganizing work stations.

But that’s not all: The digital assembly instruction system is a fully integrated solution for your production and combines logistics, manufacturing, and quality assurance. Data exchange is performed in real time via the direct connection to the ERP system. Whether worker self-inspection, quantity notifications, or automated replenishment, the various components of the digital assembly instruction system facilitate networked and automated production.

Visual assistance in production

Information directly at the assembly work station—in the right place at the right time

Individual customer needs, the desire for product diversity, and delivering high quality at competitive prices: the demands placed on manufacturing companies are in a state of flux and present a number of challenges. The future lies in automated and networked manufacturing—in which workers are optimally assisted and provided with information.

The L-mobile digital assembly instruction system provides all information relevant to manufacturing as and when it is needed. This prevents errors and simultaneously achieves a high level of process reliability. In addition, quality assurance is performed via integrated quality data collection, where the user is prompted to provide predefined data during the manufacturing process (worker self-inspection).

Our system for worker guidance in assembly enables you to produce small quantities in succession—without reorganizing work stations. But that’s not all, as your personnel also benefit from a high level of convenience when using the work station.

Simple explanation of digital work instructions

Digital worker guidance with step-by-step instructions

Relevant and up-to-date order information at a glance

High level of quality assurance through integrated checklists

End-to-end data transparency in the manufacturing process

Simple digital management of documents

Time savings and maximum accuracy

Digital work instructions in assembly—how does this work?

The display area of the assembly work stations can be freely configured. This means that specific order-related documents from other systems can be displayed during assembly. These systems could include a data management system (DMS), a business intelligence tool, or the integration of auto ID technologies, for example. The L-mobile SCADA server handles the logic of all these elements working together.

As soon as the order has been identified via the RFID reader and started, the associated bill of material from the ERP system can be displayed. It is then clear to production personnel which materials they need to retrieve (e.g. from point-of-use storage) to complete the assembly order.

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L-mobile digital production – Worker assistance system Order-based assembly instructions

L-mobile digital production – Worker assistance system Digital assembly instructions

Automation is enabled through the use of appropriate RFID readers at the assembly work station and for the respective order (e.g. by attaching an E-Label with RFID label to the respective small load carrier). When an assembly order, e.g. in the form of a prepicked small load carrier, arrives at the digital assembly instruction system, it is automatically identified by means of an integrated RFID transponder and can be called up via a terminal.

The display on the monitor of the assembly work station system automatically switches to the identified order and digital assembly instructions guide the assembly worker step by step through the production process. This improves process reliability. The type of digital work instructions that are provided on screen can be defined on a customer- and product-specific basis.

Since all the necessary assembly instructions and files are displayed automatically on screen, production personnel are able to perform their work intuitively and without any lengthy training on the digital assembly instruction systems. The order-related assembly instructions can include a variety of different information.

Customer- or item-specific work instructions from the ERP system or a data management system (DMS) can also be displayed. It is very important to have this information available in the assembly process, especially in the case of small-scale and extremely small-scale manufacturing or customizations right down to lot size 1. To help visualize the individual assembly steps, digital worker guidance also supports simple depictions of complex order information in the form of graphics, (CAD) drawings, photos, or videos.

L-mobile Werkerassistenzsystem - System zur digitalen Montage

Components of the digital assembly instruction system

Modules for a successful digital manufacturing process

Step-by-step assembly instructions
The digital assembly instruction system shows the appropriate information for each order, thus contributing to a smooth assembly process. Step-by-step instructions guide the worker reliably through the manufacturing process. Additional prompts, e.g. regarding hazardous materials or handling, ensure the person at the assembly work station is always kept informed and up to date.
Document display
Whether 3D drawings, photos, or videos, the digital assembly instruction system is connected to your DMS and therefore always provides the most up-to-date and relevant documents for manufacturing. Outdated documents and laborious document distribution are a thing of the past. It is however still possible to print out a document if needed.
Quality data collection and worker self-inspection
The digital assembly instruction system features integrated quality data collection, which enables quality assurance to be performed during manufacturing. Individual inspection plans can be created and edited in L-mobile, which are then consulted at specific points in the manufacturing process. Measured values can be recorded by personnel and also via a signal data interface (e.g. for everything from scales to complex test benches). Worker self-inspection not only enables you to document the quality assurance measures carried out, but also allows you to define escalations for specific limits and intervene accordingly.
Production data collection
Quantity notifications can be recorded directly in the digital assembly instruction system via production data collection and reported back to the ERP system in real time. This ensures data transparency in your manufacturing, as the status of your orders is always up to date and available in the ERP system. In the case of overlapping manufacturing orders, the entire process chain also benefits from efficient postings. Scrap quantities are qualified and posted directly during manufacturing. If desired, this can result in blocked stock which can later be reworked or scrapped.
Display of machine data
If signal data is available via machine data collection, it can also be displayed in our digital system for worker guidance. This can provide additional support for the user. The presentation of these key figures (e.g. as graphs or individual values) can be customized and visualized accordingly.
Automated replenishment with E-Kanban
An integrated Kanban solution enables you to ensure that the work station is constantly supplied with materials—despite fluctuating material requirements in manufacturing. This supply is fully automated and posted in the ERP system in real time. RFID solutions, such as electronic Kanban racks or mailboxes, are the key to this function.
Empties
With the supply process being fully integrated with your manufacturing, notifications can be sent manually or automatically via the system. This means that the required empties are requested at the right time and replenished by logistics.
Labeling
The L-mobile digital assembly instruction system also enables the automated printing of labels at the respective work stations or as part of internal logistics. Using auto ID technologies like RFID, the appropriate label is created for each container or individual part directly during manufacturing. Whether specific labels for items, customers, or unloading points, label printing can be fully configured.
Cross-departmental communication
L-mobile Collaborate, our integrated messaging tool, facilitates communication across all departments. The recipients can include individuals as well as departments, manufacturing orders, items, or work stations. Hotline groups can also be defined and addressed directly from manufacturing. Another practical feature is that data from the ERP system can easily be included in a message.

Contact us now to discuss concept creation

Are you looking to use a digital assembly instruction system in your company? Here are the next steps you need to take

Personal consultation with the L-mobile sales team

Development of a rough concept in collaboration with our solution architects

L-mobile Implementation Concept (LIC): detailed concept creation including investment framework and benefit calculation

The next steps then build on each other based on your individual needs and requirements. To start with, the initial requirements for your digital assembly instruction system will be clarified in a non-binding consultation with our L-mobile sales team. This is then followed by the creation of a rough concept for your project as well as an L-mobile Implementation Concept (LIC).

During the consultation and concept creation stages, optimization potential will be revealed. You will get an overview of the aspects that need to be taken into consideration for successful implementation. As part of the L-mobile LIC, we will work with you to develop a concrete project plan—including cost and investment frameworks and benefit calculation. The benefits and the payback period of the project (ROI) will thus be determined.

L-mobile production simply integrated with your ERP

Our software solution offers standard interfaces for all popular ERP systems.

Technical highlights of our software solution

Real-time data exchange with the ERP system

Automated supply with replenishment

Connection of various third-party systems (DMS, QA, 2D/3D viewer, video player, etc.)

Link for order feedback (L-mobile production data collection)

Automatic display of the correct assembly instructions

Pick-by-Light technology provides maximum accuracy

Experience the L-mobile digital assembly instruction system at our live events

Register now for free

L-mobile video screen

Flexible production right down to lot size 1

Using an assembly work station system to support the manufacturing of small lot sizes

Definition Optimum lot size Solution

What exactly is a lot size?

The term lot size 1 is synonymous with mass customization and refers to the manufacture of custom-made products. The lot size, in turn, describes the combined number of pieces of a particular product type or model (lot) that are manufactured in series without interruption.

Due to the increasing diversity of products and variants in manufacturing, companies are faced with the challenge of adapting to customer requests for customizations. The digitalization and automation of production with the help of Industry 4.0 technologies is absolutely essential in order to gain an advantage over competitors with lot size 1.

L-mobile digital production – The worker assistance system supports your employees working in production with information

The optimum lot size for customized production

L-mobile digital production – Manufacturing from small lot sizes to lot size 1 using the worker assistance system

For decades, manufacturing companies have been trying to determine the optimum lot size (i.e. the number of pieces of a particular product at which the unit costs are the lowest) in order to make the manufacturing of a lot as cost-effective as possible. For manufacturing processes without technological support, the optimum lot size is almost always greater than 1. This is due to the high costs associated with the frequent retooling of production facilities.

From an economic point of view, it therefore makes sense to produce large lots. However, this also results in high warehouse stock levels and, consequently, escalating storage costs. The challenge with lot size 1 is to ensure profitable and economical production, despite the complexity of individual small-scale and extremely small-scale manufacturing, while simultaneously providing customization options for products.

Efficient production of small lot sizes with the digital assembly instruction system

To remain competitive, manufacturing companies must adopt modern manufacturing processes in order to meet the growing demand for customizations and custom-made products. Mass producers have little choice but to retool their production in order to accommodate a wider range of variants and customized made-to-order products.

The digital assembly instruction system from L-mobile facilitates automated working methods. This enables you to realize customized production for individual customers, right through to small-scale and extremely small-scale manufacturing. The user-friendly provision of information directly at the assembly work station means that workers can also produce small lot sizes quickly and flexibly in succession.

L-mobile ife Institute innovation award lot size 1

Visit our Digital Factory

Experience the digital assembly instruction system live in the L-mobile Digital Factory. Visit our Digital Factory and see how an automated and networked assembly work station operates.

The digital assembly work station includes a touchscreen/production data collection screen, an RFID antenna, WERMA lights, a c-parts rack with Pick-by-Light devices, an E-Kanban mailbox, and E-Kanban cards. All devices are connected to the Microsoft Azure platform (Internet of Things/connectivity platform) so that real-time data can be collected during the manufacturing/assembly process.

RFID technologies and UWB (ultra-wideband) technology facilitate the automatic identification of the assembly order with digital assembly instructions on the operator terminal. As a result, order documents are captured and displayed digitally. Production data is loaded automatically and is made available to the worker at the digital work station. Variants can be produced without interruptions or long search times. This results in a more efficient and optimized design of all assembly work station systems. Connection to the Microsoft Azure platform makes it possible to connect and manage devices in the Digital Factory. The data can be evaluated and analyzed using Microsoft Power BI.

L-mobile Digital Factory – Paperless production Work stations

Manual assembly with digital work instructions—what does that actually involve?

In our Industry 4.0 podcast, Jens Malso, manufacturing expert and Managing Director of L-mobile Systeme GmbH & Co. KG, talks about the use of digital work instructions in assembly. Who needs a digital assembly work station and what role do auto ID technologies play?

He also looks at who could benefit from a system for worker self-inspection and the IT infrastructure and technologies that are required. Finally, our podcast guest shares tips on the best way to get started on such a project and shares the three major benefits of this approach.

Optimized material flow with Pick-by-Light and E-Kanban

Guided withdrawal of material with Pick-by-Light

Point-of-use storage with Pick-to-Light on the digital assembly instruction system – Error-free assembly processes

In addition to auto ID technology for automatic order identification at the assembly work station system, the digital assembly work station also has an integrated Pick-by-Light system. The Pick-by-Light technology at the assembly work station uses an LED signal to show production personnel when c-parts need to be picked from the point-of-use storage for an assembly step. So it is no longer even necessary for the worker to consult the bill of material in detail.

As the completed assembly steps are confirmed via the touchscreen, the error rate of incorrectly assembled individual parts is reduced to a minimum through the use of Pick-by-Light technology. This in turn enables manufacturing companies to integrate new personnel without lengthy training. Furthermore, the posting of the withdrawal of material to the ERP system can be directly connected to the Pick-by-Light modules.

If point-of-use storage has to be reorganized due to changes in the process or other events, with the Pick-by-Light modules used by L-mobile there is no need to rewire the entire assembly system. The modules are controlled wirelessly and storage bins can be assigned to items via an L-mobile input interface. You are thus able to quickly and independently reorganize the storage bins at a digital assembly instruction system.

L-mobile Digital Factory—paperless production: efficient and error-free picking with Pick-by-Light — Pick-by-Light

Initiation of replenishment processes

Software for digital assembly

When the withdrawal of material is confirmed at the Pick-by-Light modules, this material consumption is directly posted to the ERP system in real time, and the replenishment process for point-of-use storage at the work station is automatically initiated.

An L-mobile warehouse function can be used here. For example, a list of the work stations that require material can be displayed on the mobile handheld device of logistics personnel, so that stock can be transferred to those locations. This frees up assembly personnel to concentrate on their work, which significantly increases productivity.

Another way of ensuring the replenishment of materials is to use an electronic Kanban system. By using an RFID Kanban rack, the ordering process can be fully automated and seamlessly integrated with the ERP system. You only need two components to adapt your point-of-use storage for automated replenishment with E-Kanban. The first is a rack equipped with an RFID antenna (for recognizing the RFID tags of load carriers in the rack) and an RFID reader. The RFID reader registers the transponder and transmitter so that the information that is read can be forwarded for data transfer to the ERP system. The second component are the load carriers, which are also equipped with unique RFID tags that connect them to the ERP system.

L-mobile E-Kanban, E-Kanban with RFID — E-Kanban: automated replenishment with RFID

Equip your assembly processes for digital transformation

Using our MES solutions for machine and production data collection, all operation and quantity notifications are recorded automatically and transferred directly to the connected ERP system. As an MES module, the digital assembly instruction system enables you to produce made-to-order products as well as customizations at the same assembly work station.

L-mobile, digital warehouse management, mobile warehouse management add-on, Issue Production — Production SAP Business One

L-mobile Digital Production Data Collection Machine Data Collection Teaser — Machine Data Collection

L-mobile digital production data collection QA teaser — Quality data collection

Successfully navigate the path to becoming a smart factory through networked processes

L-mobile is your strong partner and Industry 4.0 expert on the road to digitalization

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Digital production references

L-mobile case study: Digital warehouse management, warehouse ready for Infor COM, Mack Alu-Systeme GmbH

FoamPartner Germany GmbH - Recticel En

Fritz Stiefel Industrie-Vertretungen GmbH