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Operator guidance, automatic optical inspection
and documentation in manual production

SK Assembly: Smart Klaus for manual mounting workstations

Smart Klaus SK Assembly guides the worker step by step through the manufacturing process. He checks every single step in real time and warns immediately if an error occurs.

Optionally, a digital production log can be created automatically.

  • The inspection and work instructions are digitally stored.
  • The latest inspection and work instructions are always applied and followed.
  • Waste, rework and complaints are avoided.
  • Reduced effort for manufacturing documentation.
  • Productivity increases.
  • The error rate decreases.
  • The training effort for employees is reduced

Use case:

"Since Smart Klaus has been supporting our workers during assembly, error rates and the number of complaints have dropped significantly."
Peter Sawatzky, Technical Manager

At MANN+HUMMEL International GmbH & Co. KG, Smart Klaus ensures the quality of automotive filters.

Many manual assembly steps are required for the assembly of automotive filters. These are made easier and safer by Smart Klaus.

The need for expensive changing devices with failure-prone sensory components has been significantly reduced. This also shortens setup times.

At the same time, the number of quality checks during the assembly process has been significantly increased. Error messages are output in real time so that the worker can correct them immediately.

The digital work instructions stored in Smart Klaus shorten the training times for new products and new employees. Variant management has also become easier.


More use cases


  • Simple teach-in of new or modified assembly instructions
  • Step-by-step instruction of the worker on the screen
  • Optical inspection of each individual assembly step
  • Automatic switching on after successful execution of an assembly step
  • Error message in case of faulty or forgotten assembly steps


  • Automatic documentation of all assembly steps
  • Integration of digital assembly tools
  • Marking of points to be mounted by laser
  • Interface to the company IT for seamless integration into your production control


Technical information

(Illustration contains special accessories)

The assistance system is optionally available with or without a work table. All components can also be easily mounted on existing worktables.

 Image processing computer

Dimensions (l x w x h):550 x 440 x 155 mm
Weight:15 kg
Voltage range:110-230 V, 50/60 Hz
Power consumption:max. 1,500 W including peripheral devices
Fuse:10 A at 230 V, 16 A at 110 V

AMD Ryzen 7 5800X, 3,8 GHz, 8 cores 16 threads

Random access memory:16 GB
Hard disk:2 x 512 GB SSD, configured as RAID 1
Operating system:Windows 10 Professional 2019 LTSC
External Connections:

6 x USB 3.2

2 x USB 3.2 Type-C

2 x USB 2.0

2 x RJ45 GigaBit
4 switched cold device outputs (total max. 1,000 W)



Image resolution:20 MPixel
Frame rate:18 fps at full resolution

Other camera types, up to a resolution of 42 MPixel, are available on request.

Field of view and detection accuracy

The field of view of the camera and the detection accuracy depend on the working distance and the focal length of the lens used. The specified values ​​for the field of vision apply at a working distance of 1,200 mm. The values ​​for the detection accuracy are practical experience, in which Smart Klaus works reliably in a typical industrial environment. The values ​​that can be achieved under optimal environmental conditions are given in parentheses below.

Focal length:16 mm12 mm8,5 mm3.5 mm
Field of view:320 x 240 mm640 x 480 mm960 x 720 mm2,240 x 1,680 mm
Detection accuracy:0.6 mm
(0.06 mm)
1.3 mm
(0.1 mm)
2.0 mm
(0.2 mm)
4.5 mm
(0.4 mm)

Other focal lengths are available on request.


The lighting is prepared for easy attachment to industry-typical aluminum profiles.

Dimensions(l x w x h):1,200 x 800 x 140 mm (without camera adapter)
Weight:15 kg
Power consumtion:70 W
Luminous flux:ca. 7,000 Lumen
Illuminance on the work surface:ca. 2,500 Lux
Light temperature:6.000 K (cold white)



Screen size:21.5 inches
Resolution:1,920 x 1,080 Pixel
Touch-Technologie:Projected capacitive, 10 point multi-touch ( can be operated with gloves)