Frequently asked questions

Find all relevant information about the Smart Klaus worker assistance system here.

All about Smart Klaus

All questions about the worker assistance system


What is a worker assistance system?

A worker assistance system supports employees in their daily manual production tasks. Real-time visual, step-by-step instructions safely guide individuals through complete production processes. In case of errors or detected deviations, audiovisual instructions for error correction are promptly displayed. The inclusion of components like sensors, cameras, and software ensures process safety. This system enhances efficiency and guarantees production quality.

What is Smart Klaus?

Smart Klaus is the camera-based premium worker assistance system for manual production.

The system accompanies employees in their daily tasks from goods receipt to the outgoing goods department. Smart Klaus consistently and autonomously monitors and records all procedural sequences, enhancing efficiency and guaranteeing precision in manual production. By minimizing the error rate to zero PPM (parts per million), Smart Klaus effectively addresses the challenge of skilled labor shortages.


How does the Smart Klaus worker assistance system function?

Smart Klaus navigates workers systematically through manual production processes with the aid of digital work instructions and continuous optical monitoring. The sophisticated image processing software verifies the accuracy of each work step, offering immediate feedback. Real-time audiovisual notifications are delivered after each step, indicating errors or confirming correctness.

What components does the Smart Klaus consist of?

The worker assistance system is based on various components:

  • Powerful image processing software, customized for manual production in industrial environments.
  • High-quality image processing computer with Windows Enterprise operating system, a powerful processor and extensive memory for optimized performance.
  • A camera with a resolution of 20 megapixels and a frame rate of 18 images per second.
  • Lighting with an output of 70 watts and a brightness of 7000 lumens.
  • An anti-reflective and chemically hardened control monitor in 29 inches.
  • Ergonomic touch monitor, 13 inch for interactive assembly instructions.

The worker assistance system's components can be effortlessly installed onto existing worktables. These mentioned elements are adaptable to individual requirements, and there are also various expansion possibilities (outlined in point 7 "What expansion options are there?")

What does a workplace with Smart Klaus look like?

Typically, a Smart Klaus workstation comprises the previously mentioned components. Yet, due to its modular design, the worker assistance system can be flexibly adjusted to accommodate a diverse array of workstations. This adaptability allows for the customization of the system to meet specific requirements and needs.

In which work environments can the worker assistance system be used?

Smart Klaus is presently employed across diverse industrial work settings, spanning conveyor belt operations, line production, and individualized manufacturing.

Its modular design facilitates personalized adjustments, allowing the system to be tailored to a broad spectrum of workstations.

What expansion options are there?

Smart Klaus is more than just a product - it is a holistic solution that revolutionizes your working environment. With a wide range of extensions, Smart Klaus offers a flexible and efficient solution for your industrial requirements.

We offer the following add-ons :

  • Pick-by-Light system
  • PanTilt camera
  • Projector
  • Connection of external digital tools & measuring devices
  • Automatic documentation and dashboard
  • RGB underlight for improved contrast
  • Interface to your ERP, MES and PPS system.
What types of digital tools can be connected?

Smart Klaus provides an interface designed for the seamless integration of external tools capable of detecting features not visible to the camera. Tools such as screwdrivers, label printers, scales, and similar devices can be easily connected. This integration facilitates the digital recording and documentation of specific attributes, such as torque during screw tightening, ensuring a verifiable and traceable work process.

Does Smart Klaus have interfaces to other systems?

Yes, the worker assistance system Smart Klaus has documented OPC UA and TCP-IP interfaces that enable seamless communication with other IT systems. These interfaces can be customized according to the specific requirements of the customers.

What reporting and analysis functions does the worker assistance system offer?

Smart Klaus facilitates the creation of reports using a database, as well as in PDF and JSON formats. A comprehensive documentation of all work steps is automatically generated, with each step timestamped to ensure continuous traceability and analysis of quality.

What certifications does Smart Klaus have?

The worker assistance system Smart Klaus is certified according to international quality standards EN ISO 9001:2015 for quality management and EN ISO 12100 for machine safety.


In which industries can the worker assistance system Smart Klaus be utilized?

Smart Klaus can be employed in any industry, thanks to the modular structure of its hardware and software, along with its powerful expansion capabilities.


The worker assistance system is currently in active use in industries such as automotive, Industry, electronics, medical technology, and aerospace.

Its applications span the entire production process, from goods receipt to goods dispatch.

What products can Smart Klaus recognize?

Due to the multitude of cameras and other expansion possibilities, there are scarcely any limits to product recognition. The worker assistance system can identify even the smallest parts with features as fine as 0.01 mm, such as datamatrix codes.

Does Smart Klaus recognize my product?

Do you want to know if and how Smart Klaus can recognize your parts?

Send us your sample parts for a feasibility check and receive professional advice from us – live or via video! We provide individual, non-binding, and free consultation on our product solutions.


Contact us:

Tel. +49 721 5704495-65

E-Mail: sales(at)optimum-gmbh.de

Which model suits my production?

Smart Klaus can be deployed in any application area, thanks to the modular structure of its hardware and software, along with its powerful expansion capabilities.

Discover, in just 3 clicks with our product finder, which model is the right fit for you and your production.

What tasks and workflows does Smart Klaus support?

The worker assistance system supports a variety of tasks throughout the entire value chain to ensure quality and efficiency.

In the goods receipt area, the system enables:

  • Identification of products using barcodes and QR codes
  • Quality controls by verifying product features.
  • Automatic data capture and documentation.
  • Display of storage locations and automatic goods posting.


For assembly and THT processes, the worker assistance system offers the following functions:

  • Step-by-step instructions supported by accompanying images and/or videos.
  • Real-time guidance and notifications in case of errors.
  • Continuous, automatic optical quality control.
  • Automatic collection of OEE (Overall Equipment Effectiveness) data.
  • Automatic documentation and logging of performed assembly processes.



In the end-of-line process, the worker assistance system provides:

  • Automatic optical inspection of the final product, eliminating the need for downstream 4-eye checks.
  • Detection of errors and provision of on-screen correction instructions.
  • Data capture at the end of the production line for automated data collection (performance analyses).
  • Prevention of complaints through preventive measures.



In the outgoing goods area, the worker assistance system supports:

  • Guidance for the picking process to ensure smooth assembly of goods.
  • Automatic update of inventory in the database.
  • Automatic generation of labels for clear identification.
  • Seamless documentation and traceability of outgoing shipments for transparent tracking.


For more information on all modules, please visit our product overview page.

What advantages does a worker assistance system offer?

A worker assistance system provides numerous advantages, including::

  • Digital and measurable process workflows
  • 0 ppm error rate
  • Automatic documentation
  • Elimination of rejects, complaints, or rework
  • Increased productivity and enhanced efficiency
  • Maximized profit and competitive advantages
  • Anytime access to centralized, flexible digital manufacturing information
  • Flexible employee deployment and addressing skilled labor shortages
How does the worker assistance system ensure the quality of production?

The worker assistance system Smart Klaus ensures quality in several ways:

  • Real-time monitoring: Continuous monitoring of work processes enables the immediate detection of potential quality issues.
  • Optical identification: The system identifies and checks components in real-time, minimizing errors and eliminating confusion.
  • Digital support: It provides digital alerts or instructions for addressing quality issues as they arise, allowing for immediate corrections.

Continuous improvement: Automatic documentation enables the traceability, analysis, and improvement of production processes to enhance quality.

How does Smart Klaus combat the shortage of skilled workers?

The worker assistance system addresses the skilled labor shortage by:

  • Making digital knowledge accessible: Every employee has access to digital knowledge, facilitating faster training of new staff. Visual instructions reduce qualification requirements as context-specific guidance is provided during work.
  • Accelerating onboarding phases: Thanks to visual instructions, the training of new employees can be expedited by up to 75%.
  • Flexible deployment of employees: Staff can be deployed in various roles without the need for extensive specialized training. This promotes the development of product experts within the team.
  • Attracting young talent through modern technologies: The integration of modern technologies attracts young talent and makes industrial jobs appealing.
How is the privacy of employees protected?

The worker assistance System Smart Klaus ensures the protection of privacy through:

  • Data protection consideration: Only information necessary for work assistance is captured, consistently adhering to applicable data protection regulations.
  • Limited recording: Only workstations are filmed, with no capture of personal characteristics of the employees.
  • Preserved anonymity: Recordings do not contain individual personal data of the employees.
  • Targeted images for specific work steps: The option to create targeted images for individual work steps ensures focused and purposeful documentation without unnecessary recordings.


Can I test the worker assistance system before buying?

Of course, you are welcome to test the system before purchasing.

You can either get to know the system at a trade fair, test it at our premises or evaluate it in your own production facility with a rental model.

Our rental option enables a 3-month trial of our product. Moreover, we extend the opportunity to acquire Smart Klaus at the conclusion of the rental period, with 50% of the already paid costs being applied towards your purchase.

What is the purchase process for Smart Klaus?

The process begins with your inquiry - you can contact us by e-mail or telephone.

Once we have received your inquiry, we will arrange a personal or telephone consultation. During this meeting, we will discuss your requirements in detail and provide you with all the relevant information about Smart Klaus.

As soon as you have decided to purchase the Smart Klaus worker assistance system, your worker assistance system will be delivered and we will support you during commissioning.

You will then receive training. Here we provide a comprehensive introduction to the operation and functionality of the system.

How does the training take place?

<meta charset="UTF-8" />Training on the worker assistance system can be carried out either directly on site at your company, virtually or at our premises. 

How fast can Smart Klaus be integrated into a production environment?

Smart Klaus delivery takes place within 4 to 8 weeks after receipt of order. As soon as your system has been set up on site, and together with you, our technicians will take care of commissioning.

The worker assistance system is immediately ready for use. Your variants can be taught in directly and are immediately valid for assembly. No special programming knowledge is required.