Digitising production: Paperless manufacturing with SOMA worker assistance

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 far more than simply scanning and digitising documents. It involves providing information and data in real time directly at the assembly workstation, as well as the ability to provide electronic feedback and documentation. The SOMA flexAssistant worker assistance system enables an efficient, digital manufacturing process through digital work instructions.

Paperless manufacturing only realises its full potential when companies not only digitise individual documents, but also automate their business processes end-to-end. flexAssistant links assembly, production and related departments into a seamless digital workflow: from the acceptance of production orders through to work instructions and the reporting of operational data, recurring steps are carried out without the need for manual intervention.

By automating business processes, you reduce error-prone manual data entry, shorten lead times and create a reliable data foundation for analysis and process improvements. Seamless integration with ERP, SAP and document management systems ensures that information reaches where it is needed in real time – across departmental boundaries.

• 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

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

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.

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

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

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

The digital transformation in Industry 4.0 enables real-time monitoring of production processes, highly automated data collection and the seamless integration of various systems. Companies that opt for paperless production benefit from reduced paper consumption, improved quality controls and faster decision-making based on real-time data. As a result, production documents remain up to date at all times in a paperless production environment and do not delay the assembly process.

By using specialised software for paperless manufacturing, such as the flexAssistant Worker Suite, companies gain a genuine competitive advantage, as they can respond more agilely and quickly to market demands. The intelligent integration of machines and processes makes manufacturing more profitable and flexible. At the same time, the digital factory conserves resources and reduces environmental impact – a benefit both ecologically and economically.