Augmented Reality Operator Guidance Platform in Assembly

[Erkan Teskancan]

The Operator Guidance Platform, developed in collaboration between Bosch Rexroth and the Belgian software company ARKITE, digitalizes manual assembly, picking, and quality control processes. Offering augmented reality (AR)-based instructions and real-time sensor feedback instead of physical documentation, the system has been made globally available with standard components of Bosch Rexroth's modular workstation systems. It aims for near-zero defect quality in complex manual operations within the electronics, aerospace, and automotive sectors.

### Augmented Reality Projection and Workflow Integration
The system guides operators through assembly steps with a "pick-to-projection" mechanism. The "Guide" mode projects AR instructions directly onto the work surface and relevant picking bins, allowing operators to focus without looking at external monitors. Auxiliary equipment such as smart tightening systems, pressing stations, and collaborative robots are synchronized in a single workflow, ensuring processes are executed in the correct sequence. Errors have been reduced by up to 90% in documented applications.

### Real-Time Validation and Vision-Based Quality Control
The "Validate" version monitors task execution instantly with 3D sensors and special algorithms. Deviations from programmed work instructions are immediately detected, providing an opportunity for instant intervention. For tasks requiring high precision, ARKITE Vision high-resolution visual sensors are used to check micro-assembly accuracy. In over 1000 applications, rework and scrap have been reduced by 80%, significantly improving first-pass yield rates.

### Modular Configuration and System Compatibility
Based on Bosch Rexroth's modular system, which meets ergonomic and high cleanliness standards, the platform offers flexible configuration and integration advantages:

• Work instructions can be uploaded quickly without requiring code
• By connecting with higher-level systems like MES and ERP, quality documentation and resource planning can be automated
• Easy integration into new and existing lines facilitates the transition to a digital supply chain

### Training Efficiency and Global Expansion
The platform shortens operator training times by up to 50%. The AR interface is used as a continuous on-the-job training tool. Furthermore, ARKITE will integrate its platform into Bosch Rexroth's Certified Excellence partner network, providing regional factory support and application expertise. This will expand digitalization in the industry and strengthen local support.