1. Smart Klaus carries out end-of-line testing for automotive suppliers
OEMs demand maximum precision and quality. Luxury car manufacturers like BMW and Mercedes, in particular, have stringent requirements for their direct suppliers.
However, the variety of models, increasing production complexity, and shortage of skilled labor often lead to errors and production overload. These errors are time-consuming, costly, and reduce the competitiveness of Tier 1 suppliers, additionally increasing pressure on employees.
To meet the ever-demanding and constantly changing requirements of OEMs, many Tier 1 suppliers in the automotive industry now rely on advanced assistance systems. Specifically, more and more worker assistance systems are being used for quality assurance in manual assembly.
This is also the case with the automotive supplier Möllertech, whose employees are now supported daily by the digital worker assistance system Smart Klaus. Since the implementation of this assistant, errors in end-of-line testing are detected in real-time and processes are automatically documented. Workers are significantly relieved, and the product quality of the Tier 1 supplier is ensured. Documentation is now also automatic and seamless.
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2. The Digital Worker Guidance at the OEM Direct Supplier
Since 2021, the digital assistance system Smart Klaus has been in use at Tier 1 supplier Möllertech. Currently, five inspection systems assist in checking various items: from small door sills, upper pillars, and glove box and center console assemblies to large B-pillars. In this application, the worker assistance system ensures the subsequent optical end-of-line inspection.
As with many other suppliers, Möllertech's production was characterized by a high susceptibility to errors. This led to the introduction of the worker assistance system Smart Klaus.
Jan Roman, Quality Manager at Möllertech, explains in an interview: "In the past, workers themselves ensured the quality of the plastic refinements. However, the demands have increased significantly over the last 10 years." This resulted in more frequent complaints. Although organizational measures such as sensors in tools and cutting devices were implemented to detect errors and support employees, these were not entirely successful, and defective components continued to occur.
3. The manual Assembly Process at Möllertech: Before and After Smart Klaus
Since the introduction of the digital assistance system Smart Klaus, the assembly process at Möllertech has become significantly safer and more efficient.
Prior to the implementation of the various SK systems, parts were manually removed from the conveyor belt, assembled, and packaged. Each worker was responsible for their own section, and there was no independent quality control instance. This often led to complaints, as errors were only discovered later.
With the implementation of the digital assistance system, the process now works as follows: Parts come directly from the injection molding machine to the workers unassembled. Clips, clamps, and foam pads are then attached, followed by stickers and mats. At some stations, one worker handles the left side and another the right side. Once the assembly process is completed, the parts are placed under the camera of the worker assistance system for inspection.
Smarts Klaus now checks downstream to ensure that all parts are correctly attached and assembled. If something is not properly mounted, the system immediately issues a warning. Only when the error has been rectified and the assembly piece is error-free is automatic documentation is generated and the part can be packed for dispatch.
Doreen Dittmar, Team Leader at Möllertech, tells us in an interview: "Previously, whenever a faulty part appeared, we had to block an entire pallet or even the entire production line. These parts were then placed within a blocking area and had to be processed - which meant costs and additional work. With Smart Klaus in action, it's done right from the start." The digital assistance system prevents rejects and complaints from occurring in the first place.
4. Benefits of the Digital Assistance System
The introduction of the worker assistance system Smart Klaus has brought numerous advantages for Möllertech, both at the employee and management levels.
Error reduction
Through real-time data processing and live feedback, the system nearly eliminates human errors. Any deviation from the standard is detected immediately and must be corrected before proceeding to packaging and commissioning.
A production employee explains when the system triggers an alarm: "If the square clips are not properly inserted or if they are crooked instead of straight. Also, if the labels (right and left) are not correctly applied, or if the parts are not properly molded, Smart Klaus detects that too." She also mentions, "Der Smart Klaus sees if I have inserted the wrong mats. They look almost identical, but there are two different variants."
The downstream optical 100% inspection thus ensures product quality, independent of the employees.
Traceability
All parts that pass the inspection are automatically documented by the worker assistance system, enabling seamless traceability. This is particularly important for quality assurance.
Jan Roman, Quality Manager at Möllertech, explains, "Traceability has the significant advantage of pinpointing a part within a complaint. Complaints can even be rejected, as the precise documentation with images proves when errors and damages occurred outside our process."
Simplified employee training
In addition, Smart Klaus has considerably simplified the training of new and foreign-language employees. The new employees learn to understand the assembly process visually through the visual feedback. If they make mistakes, they are visually pointed out to correct them - all without language barriers and comprehension problems.
This not only shortens the induction period, but also drastically reduces the error rate of new employees.
Higher Production Efficiency
The assistance system allows employees to focus on their core tasks without constantly worrying about quality checks, leading to higher production efficiency.
Cost Reduction
By reducing errors and complaints, the costs for reworking and recalls are decreased considerably. The return on investment for Möllertech with Smart Klaus was achieved within 18 months.
Sustainability
By reducing reject rates and errors, Smart Klaus also contributes to sustainability. Fewer faulty parts mean less waste of resources and more environmentally friendly production. Automated and digital documentation means paperless production.
Employee relief
Smart Klaus relieves employees from constant inspection, quality control, and documentation, reducing stress and allowing them to perform their core work more efficiently. The downstream inspections are entirely eliminated, as Smart Klaus now handles them.
Flexibility and Adaptability
The worker assistance system can be flexibly adapted to changing requirements and new projects. This is a crucial advantage over static or sensor-based inspection systems, as it can quickly and easily adjust to new product variants and production processes. New variants can be integrated and made valid within a day.
5. Voices of Production: experiences with the worker assistance system
The implementation of the digital assistance system was initially regarded somewhat ambivalently by employees. Some were skeptical about the new technology and feared that it could drastically change the way they worked. But after a short time, the positive voices prevailed.
Birgit Herta, production worker at Möllertech, reports: "At first I was unsure whether Smart Klaus would really be a help. But now I can't imagine working without him. He takes so much work off our hands and gives us the certainty that everything is assembled correctly."
Team leader Doreen Dittmar is also pleased: "It's much better with Smart Klaus, as fewer complaints come in and all queries run through the system. In the past, we always had to block an entire pallet if a defective part was found. Now everything is done correctly right away."
<meta charset="UTF-8" />Jan Roman, Quality Manager at Möllertech, emphasizes the flexibility and effectiveness of the system: "Smart Klaus works like a digital worker in the final inspection, and is 100% effective. The introduction of this system has eliminated the self-inspection by employees and significantly increased inspection quality."
Tom Weber, Injection Molding Manufacturing Manager, adds: "In the past, testing was always a manual process. Many complaints resulted from mixed-up parts or missing attachments. With Smart Klaus, we have drastically reduced these problems and increased documentation reliability."
6. Future prospects with the digital assistance system
Smart Klaus has taken quality assurance for Tier 1 suppliers to a new level. The introduction of the digital assistance system has shown how technology can revolutionize efficiency and quality in manual assembly. Möllertech is already planning to use the digital worker assistant in other areas such as logistics and shipping in order to further optimize processes.
Smart Klaus has proven to be an indispensable tool in modern assembly. From error reduction and increased productivity to the positive feedback from employees - the digital assistance system has fundamentally changed the way Möllertech works.
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