their instructions to be color matched or to convey critical safety instruc- tions in a vibrant red. The engineering group needed a practical solution for the problem of non-standardized work and determined that augmented reality work instructions would optimize the process.
This task was an ideal opportunity to demonstrate the fl exibility, power and customizability of digital projec- tion technology—not only to guide, but to connect with precision sensors within the process to ensure every step would be completed correctly.
Flexible, Scalable, Portable In this case, the solution is a tech- nology that has been utilized to great effect in a wide range of industries and applications: Light Guide Systems (LGS). LGS is a fl exible, scalable, and portable product that combines industrial-strength projection technology with sophisticated proprietary software to provide an intuitive and interactive visual guide for assembly, inspection, training and logistics.
In this instance LGS shows when and where glue must be applied.
visual template, this project pushed our whole team forward to think of new ways to get the most out of projection technology.
The system projects a digital operating “canvas” directly onto the work surface, providing workers with audio and visual prompts, guidance, pacing and direction. A “No Faults Forward” system design ensures that the right parts are used, the approved operator sequence is followed, and the correct processes are executed safely, correctly and effi ciently. LGS’s intelligent lighting and projection guidance provides users with step-by-step confi rmation—not only does the system show the operator what to do, it confi rms that the task has been completed.
In addition to the detailed visual guidance to ensure that
the correct parts are put together in the right way and in the right order, this project presented a number of unique chal- lenges. Tools like programmable machine vision cameras, laser trackers, and torque guns can be integrated into the system to provide precision confi rmation that tasks like pipe alignment, bolt sequencing and tightening are performed cor- rectly. The result is the error-proofi ng of critical processes. Additionally, blueprints, instructional videos and even a virtual tape measure for key steps can be projected directly onto the work surface. From demonstrating a specifi c welding process to ensuring a pipe is the correct length to using a 3D
LGS also provides valuable data from each step in each
process, generating insights that drive evaluation and effi cien- cies. Particularly in a manufacturing situation with this much variation, the ability to measure cycle time at each step ensures that bottlenecks are identifi ed quickly and can drive process and procedural improvement. In similar customized assembly environments, errors are reduced by 80%, cycle time is reduced by 40% and throughput increased by more than 80%. The step-by-step assembly protocol in LGS is designed in a way that optimizes safety, a feature that was particularly im- portant due to the scale of this situation. Projected reminders
87 — Energy Manufacturing 2015
Variations upon Variations The other signifi cant challenge in this scenario is the varia- tion between each customized skid. In this instance, multiple customized programs can be easily built into the system by the customer using LGS’s visual interface. Users on the fac- tory fl oor can simply use a touch screen monitor or bar code scanner to switch between processes depending on which module variation is being assembled.
At 30 × 20' (9 × 6 m), creating each module required the intricate assembly and fabrication of numerous parts.
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