Paperless manufacturing with SOMA flexAssistant
The future of paperless manufacturing

The innovative SOMA flexAssistant enables the digitisation of manufacturing and assembly processes in a cost-efficient and flexible manner.

Digitising production: Paperless manufacturing with SOMA work assistance

The advent of paperless manufacturing is transforming production processes. With worker assistance systems in manual assembly and manufacturing, employees can complete their tasks more efficiently and with fewer errors. flexAssistant provides real-time instructions and assistance directly at the workplace, eliminating the need for physical or paper documents.

Digitalisation has brought about a profound change in industry and increased the need for paperless manufacturing, production and assembly. Companies are faced with the challenge of optimising their manufacturing processes and replacing inefficient paper-based workflows with digital solutions. In numerous manufacturing companies, the transition to paperless manufacturing is seen as a pioneering step towards a digitalised future.

However, effective digital production requires much more than just scanning and electronically capturing documents. It involves providing information and data in real time directly at the assembly workplace, as well as the option of electronic feedback and documentation. The SOMA flexAssistant worker assistance system enables an efficient manufacturing process through digital work instructions.

Advantages of paperless manufacturing

Advantages of paperless manufacturing with the SOMA flexAssistant worker assistance system

Paperless manufacturing offers many advantages, enabling faster production and assembly, improved quality control and increased flexibility of business processes. Digital and paperless manufacturing enables companies to respond more effectively to customer requirements and increase their competitiveness. By implementing paperless manufacturing methods, you increase efficiency through automated processes, benefit from reduced susceptibility to errors, better traceability of production data, lower operating costs and faster responsiveness to changing market requirements.

Digital production and manufacturing in companies

Holistic automation is crucial to the success of paperless manufacturing and production. Companies should not just digitise individual process steps, but digitally transform their entire manufacturing and assembly operations. By connecting their ERP system, document management system and other digital components, companies can ensure efficient and transparent production, manufacturing and semi-automatic or manual assembly across different departments.

  • Greater contribution to sustainability
  • Cost savings
  • Greater flexibility
  • Shorter throughput times
  • Traceability of individual process steps
  • Quality assurance
  • Faster adaptation of production documents
  • Product and process changes are always up to date
  • Avoidance of delays
  • Faster response

Advantages of paperless assembly for employees

Eliminating the need to search for order-related documents can lead to increased efficiency in order processing. By digitising production documents and work instructions, employees can quickly and easily access the information they need, saving time and resources. In addition, errors and delays can be minimised because the required documents are always up-to-date and easily accessible. Overall, paperless processes and digital instructions can increase the quality of work in the production process and contribute to improving employee motivation and satisfaction.

  • No more searching for order-related documents such as drawings, work plans and production documents
  • Option of digital display of order progress and any remaining work
  • Labour cost savings and creation of employee capacity for other tasks
  • Increased employee satisfaction and motivation due to lower error rate
  • Faster familiarisation and training due to digital access to all necessary information at the assembly workstation
Do you have questions about our worker assistance and pick-by-light system as individual solutions for your production? We are happy to help. Contact me

Advice on the flexAssistant worker assistance system

Do you have questions about our worker assistance system as an individual solution for your paperless manufacturing? We are happy to help. Please contact me.

Your personal contact partner

Michael Penzel
Phone: +49 2355 50828-973
Email: m.penzel@soma.de

Problems and disadvantages of paper-based processes

Disadvantages of paper-based assembly processes
Conventional manufacturing methods based on paper-based processes often encounter a number of challenges and address a variety of issues in manufacturing and manual assembly. These include manual data entry, error-prone manufacturing processes and confusing checklists, longer lead times, limited transparency and traceability of production data, quality loss due to different document versions, and higher costs for paper document management and storage.
Paper-based manufacturing often results in long production times and inefficient workflows. Documents have to be distributed and processed manually, which can lead to delays and errors. By digitising documents and work instructions, companies can ensure that employees always have access to the latest information and avoid errors caused by outdated production documents. Paperless assembly enables faster information provision by replacing paper-based processes with digital ones.

Paperless production: how paperless manufacturing works

How exactly does paperless assembly work with the SOMA flexAssistant worker assistance system? flexAssistant enables digitised assembly by providing workers with digital work instructions at the assembly workstation.

Efficient workflows through paperless manufacturing and assembly with SOMA flexAssistant

Efficient workflows and manufacturing processes for employees

By using the SOMA worker assistance system, employees can work more efficiently because they no longer have to rely on paper instructions or manuals. The flexAssistant system can also be integrated with other digital production and manufacturing systems (ERP, SAP, DMS, etc.) to ensure seamless communication and data exchange.

Using flexAssistant is extremely easy: employees start the worker assistance during their shift. After logging in, the employee receives the available work orders for the designated workstation from the work queue. The next required order can be started by entering or scanning. flexAssistant automatically generates the work steps from the production order (e.g. from SAP) and a database.

  • Transparency in production through a clear work queue
  • No separate process for production control is necessary
Papierlose Fertigung mit Schritt-für-Schritt-Anleitung in der Montage

The path to paperless manufacturing with SOMA flexAssistant

A holistic approach is required for digital manufacturing, with a consistent transition to paperless solutions. The transition to paperless assembly and production usually occurs in stages. We analyse your paper-based processes as a starting point and define the project goal in collaboration with you.

The path to paperless manufacturing and production with SOMA flexAssistant

Initial situation

Complex work processes in the assembly area due to a large scope of work, a high number of variants and complicated work instructions. This complexity has the following effects:

  • High qualification and long training periods for employees are required
  • Risk of the emergence or delayed detection of process/assembly errors
  • Productivity losses

Project objective

Introduction of a worker assistance system in production for the cognitive support of workers in the execution of their work with the following components:

  • Worker assistance through digitised and visualised work steps
  • Data acquisition and evaluation
  • Process monitoring and order feedback
  • Material withdrawal support

Project benefits

The integration of the flexAssistant worker assistance system digitises assembly and work processes.

  • Simplification and standardisation of work execution
  • Reduction of training times
  • Avoidance or real-time detection of production and assembly errors
  • Database for process evaluations and process improvements
  • Digital work instructions instead of a flood of paper

How do you switch to paperless production and manufacturing?

The new development or transition to paperless processes in assembly and production is carried out step by step. First, the system is developed, in which the digital infrastructure is designed and the necessary software for worker assistance is developed.

The next step is to create an operating concept that defines processes and procedures. To test the system in a test environment, a prototype is then built. This is followed by training for employees to prepare them for working with the new digital tools and assembly processes.

During commissioning, the system is finally integrated into the ongoing operation. Project management supports the entire changeover process to ensure that schedules and processes are adhered to, and to monitor and document implementation.

flexAssistant Werkerassistenz Ablauf einer Systementwicklung

Paperless manufacturing with SAP integration

SAP offers a wide range of software solutions that are specifically tailored to the requirements of the manufacturing industry. These solutions include functions for planning, controlling and monitoring manufacturing processes, as well as for integrating business processes along the entire value chain.

flexAssistant worker assistance with SAP

flexAssistant worker assistance with SAP

SAP offers various software solutions that are specifically tailored to the requirements of the manufacturing industry. These include S/4HANA Manufacturing, Manufacturing Execution, Integrated Business Planning, Asset Intelligence Network, ERP and others.

The implementation of SAP solutions in paperless production requires careful planning and execution to ensure a smooth transition from traditional manufacturing processes to digital methods. The advantages of an SAP integration with flexAssistant are obvious:

  • Direct evaluation of production orders from SAP in flexAssistant
  • Always the current orders in focus

Exemplary integration of SAP ERP with SOMA flexAssistant

Application server

  • SAP ERP P11: After a production order is released, a LOIPRO IDOC is generated and sent to VM.

Virtual machine (VM)

  • IDOC handler: Interprets IDOCs, forwards them to the file server and writes key data of the production order in the SQL database. Contains Theobald and NLog.
  • NLog: Creates logs, e.g. warning/error messages.
  • Theobald Connector: Receives IDOCs and converts them into XML files.
  • Graylog client: Interpreter logs and sends data to Graylog server.

Admin computer

  • SQL Editor: Used to maintain additional master data (e.g. image paths, tools) in the SQL database.
  • Test stand development environment: used to maintain additional data for special applications (e.g. pick-by-light, screwdriving processes) and to create work sequences in manual mode (without SAP connection).

File server

  • file manager: used to store image files and software versions of the flexAssistant framework. Can be operated via admin computer, among other things.

Database server

  • SQL database: contains data tables for the work queue (key data of production orders from IDOC), additional master data (e.g. tools), booking data (e.g. actual quantities).

Workstation

  • flexAssistant: GUI for workers, runs on the basis of Teststand-RunTime.
  • NLog: Creates logs (e.g. warning/error messages)
  • Graylog client: Interpreter logs and sends data to Graylog server.

Application server

  • Graylog server: Collects the logs from workstations and VMs centrally and displays their contents and key figures in a compact dashboard for the admins.

The roadmap to paperless production with an ERP system and flexAssistant

The roadmap to paperless production with an ERP system and flexAssistant

The connection between the ERP system and the flexAssistant in production means efficient work and reduces errors in assembly. Thanks to the SOMA flexAssistant worker assistance and software suite, paperless production has become a reality in the KOSTAL Drives Technology business unit, for example.

Since the changeover and integration, manual assembly and production have been running smoothly, without delays caused by paper-based processes. Printed documents are no longer necessary because production is fully digitally controlled.

Would you like to learn how KOSTAL frequency converter assembly has been digitised and how you too can eliminate paper-based processes with the help of SOMA worker assistance? Let's get in touch and have a chat about it.

Do you have questions about our worker assistance and pick-by-light system as individual solutions for your production? We are happy to help. Contact me

Advice on the flexAssistant worker assistance system

Do you have questions about our worker assistance system as an individual solution for your paperless manufacturing? We are happy to help. Please contact me.

Your personal contact partner

Michael Penzel
Phone: +49 2355 50828-973
Email: m.penzel@soma.de

Software solutions for the paperless factory and industry 4.0

Digital methods and software are revolutionising Industry 4.0 and offering numerous advantages for companies on the road to the smart factory. Implementing modern strategies can optimise processes, make production processes more economical and increase productivity.

Software solutions for the paperless factory and industry

The implementation of paperless production in modern factories

The digital transformation in Industry 4.0 enables real-time monitoring of production processes, highly automated data collection and seamless integration of various systems in manufacturing. Companies that implement paperless manufacturing benefit from reduced paper consumption, improved quality control and faster decision-making based on real-time data. By providing digital work instructions and checklists, manufacturing documents are always up to date and do not delay the assembly process due to missing paper documents.

Digitising production processes: increased efficiency and productivity

The advantages of paperless production through the use of software solutions such as the flexAssistant worker suite lead to a competitive advantage, as companies can react more agilely and responsively to market demands. Through the intelligent linking of machines and processes, production becomes more profitable and flexible. The digital factory also offers the possibility of saving resources and reducing environmental impacts, which brings both ecological and economic advantages.

Digital worker guidance and manual production rethought. Experience the SOMA flexAssistant worker assistance system with Pick by Light module.

Paperless assembly and documentation, Pick-to-Light assembly workstations and smart manufacturing

The SOMA flexAssistant worker assistance system is an industry-independent solution for your manual or semi-automated assembly. Real-time process monitoring and data exchange with your ERP, pick-by-light or pick-to-light system at the workstation and digital work instructions make the worker assistance system a flexible all-rounder for your company. Find out how flexAssistant can help your company to successfully digitise paper-based processes, reducing your environmental impact, improving employee satisfaction and increasing the profitability of your production.

Do you have questions about our worker assistance and pick-by-light system as individual solutions for your production? We are happy to help. Contact me

Advice on the flexAssistant worker assistance system

Do you have questions about our worker assistance system as an individual solution for your paperless manufacturing? We are happy to help. Please contact me.

Your personal contact partner

Michael Penzel
Phone: +49 2355 50828-973
Email: m.penzel@soma.de

All current news

The SOMA Group website offers a comprehensive source of information, including the latest publications, press releases, case studies and trade fair updates from all our business units.

Exhibition calendar

Date Exhibition / Topics Location Informationen
19. – 21. March 2024 Lubricant Expo North America
Dosing Technology
Detroit, USA Learn more
28. – 29. August 2024 all about automation
Dosing Technology, Worker Assistance
(Together with ABNOX AG)
Zurich, Switzerland Learn more
17. – 19. September 2024 Lubricant Expo Europe
Dosing Technology
Dusseldorf, Germany Learn more
08. – 11. October 2024 Motek
Dosing Technology, Worker Assistance
Stuttgart, Germany Learn more
22. – 24. October 2024 IZB
Worker Assistance (Joint stand at GWS)
Wolfsburg, Germany Learn more
20. – 21. November 2024 VDE E-Mobility Conference
Worker Assistance
Frankfurt, Germany Learn more

Discover all SOMA business units and solutions

Company website of SOMA GmbH

SOMA is an independent company under the umbrella of the KOSTAL Group and has been a system supplier of test and automation systems and manufacturer of innovative and patented dosing technology since 50 years.

Test systems and Automation

Margin pressure and ever stricter specifications are forcing companies to work as effectively and efficiently as possible. The "zero defect" requirement is the starting point of targeted test methods for fault detection.

Process reliable dosing systems

Lubricants are used in all situations where friction forces are created as a result of movements and actuations in mechanical or mechatronic products. We have suitable dosing products to ensure process reliability.