Switch to Efficient In-House Assembly of Frequency Converters Enabled by Digital Worker Assistance
KSB, a leading manufacturer of pumps and valves, had to restructure its internal assembly processes with the introduction of a new product line to become independent from external suppliers.
By implementing the camera-based worker assistance system Der Schlaue Klaus®, the company was able to complete in-house production, significantly reduce the training time for new employees, and improve the quality of its assembly processes.
KEY FACTS: KSB SE & Co. KGaA and Its Use Case
THE SOLUTION: Smart Klaus®
As part of the transition to in-house assembly for the new EtaLinePro product line, KSB decided to implement the camera-based worker assistance system Smart Klaus®. Previously, pre-assembled components were sourced externally – today, the system enables complete in-house production directly at the plant. With the digital step-by-step guidance and real-time feedback, even untrained employees can perform complex assembly processes safely, accurately, and independently. This not only increases KSB’s efficiency but also reduces its reliance on external supply chains.
PRODUCT PROFILE: System(s) in Use
USE CASE: More Insights
More Flexibility, Productivity, and Enhanced Competitiveness
In-house production allows companies to be more flexible, drive innovation, and achieve long-term competitive advantages. KSB, a leading manufacturer of pumps and valves, embodies this approach.
As part of the launch of the EtaLinePro product line, the company in the Palatinate region is transitioning to in-house production in an innovative way – and Smart Klaus® could not be a better fit.
Smart Klaus® as an Enabler
During the launch of the EtaLinePro production line and the shift to in-house manufacturing, the search began for an assistance system that would allow employees to independently and accurately handle the complex assembly of frequency converters. The decision ultimately fell on Smart Klaus®.
Before the worker assistance system was implemented in KSB’s production halls, the frequency converters were delivered pre-assembled from external suppliers and then simply mounted onto the pumps by employees.
The camera-based worker assistance system guides employees step by step through digital work instructions and provides real-time feedback. If errors occur, the system points them out, and the process can only continue once all errors have been corrected. This allows even untrained employees to take over the newly added pre-assembly of electronic components.
Experienced employees also benefit from the system. Production manager Daniel Mahn explains:
"We specifically chose Smart Klaus because it works in the background. Experienced employees don’t have to manually confirm every step; it only alerts you when something is wrong. This way, work is not interrupted during assembly."
Reducing Onboarding Time by 75%
The camera-based assistance system supports employees both during the onboarding phase and the introduction of new processes, such as assembling frequency converters.
Before the system was introduced, the onboarding phase for new employees at KSB took about a month, during which they were accompanied by experienced staff before working independently. This supervision tied up resources.
With Smart Klaus®, this has changed. After approximately one week of personal guidance, new employees can independently carry out assembly processes, with the system ensuring the quality of each step.
From the employees’ perspective, such as industrial mechanic Elvan Elbay, the digital assistance system is very positively received:
"Compared to traditional workstations, the onboarding phase is much shorter and with significantly fewer errors thanks to Smart Klaus."
Innovative Approaches in Designing a New Workplace
"We took new approaches when designing the workplace for EtaLinePro," says Ilja Braxmeier, Team Leader at KSB in Frankenthal. The unique aspect of the new in-house production is the simultaneous development of both the product and the production processes. Through parallel development, product and process planning influenced each other.
Before the optimal workstation was built, employees first tested it in a virtual production environment and then extensively with a cardboard mock-up. This allowed them to better understand individual work steps and determine requirements such as space needs along the line.
Thanks to the versatile and customizable features of Smart Klaus®, it could be seamlessly integrated despite the dynamic requirements.
Worker Assistance: An Essential Tool at KSB
The seamless integration, including connection to the company MES, is achieved through the flexible and dynamic adaptability of Smart Klaus® and KSB’s openness to innovation. Employees are thus enabled to work smoothly, which increases productivity and efficiency. This production line fits seamlessly into the lean process chain from supplier to delivery.
With this innovative solution, KSB SE & Co. KG takes another step toward progress, sustainability, and digitalization.