Augmented reality helps Gotec Group optimise manufacturing processes
Daniel Walendy, Chief Information Officer
Background
The Gotec Group is a dynamic manufacturing company with a wide range of products, which means they regularly need to reconfigure their production lines. One key element in their production is the bonding agent that is applied to various materials. While the company had previously implemented partial automation of several manufacturing processes, the critical task of properly setting spray guns continued to be done manually.
The company faced a major challenge in optimising the spray gun settings for manufacturing various components for the automotive industry. Inefficient use of material, delays in setting the production equipment, and subsequent modifications to finished products all prolonged the manufacturing times.
This process was especially challenging because a single production cycle can involve 3 to 4 changes of settings, requiring the spray guns to be reset each time. Every change required fine parameter setting, directly affecting material consumption. Additionally, the customer faced challenges in training operators at their manufacturing facilities across the world. The need for experts to travel from Poland to various continents resulted in substantial travel costs. Traditional operator training methods required these experts to be physically present at the training sites.
Project implementation process
We addressed the problem by deploying the innovative VR technology, RealWear Navigator 500 – specialised VR smart glasses designed for hands-free communication with remote experts, even in challenging production environments. These smart glasses are very durable, easy to use with voice commands, and equipped with an integrated camera that streams real-time video. This allowed experts in Poland to train operators remotely, whether they were in Mexico, China, or Slovakia, without the need for the expert’s physical presence on site.
Factory workers put on the RealWear smart glasses and remote experts monitor their work on a computer screen and provide instructions using drawings,
voice commands, or screen sharing through TeamViewer or MS Teams, which we integrated into the devices.
This combination of technologies brought about immediate improvements in operators’ work performance without disrupting the production process. As part of the Proof of Concept (PoC), we tested the solution in a real production environment to verify its functionality and efficiency. Based on the findings, we proposed additional enhancements to further boost productivity. Finally, we handed over the entire system to the client as a fully operational solution, ready for further development.
Results and benefits
improved efficiency in operator training
continuity of manufacturing processes
improved spray gun setting quality
reduction of material waste
Customer Profile
The GOTEC Group is the world’s leading specialist for surface treatments and application of bonding agents for rubber-metal/plastic parts for the automotive industry. It has 17 branches in 12 countries across Europe, the Americas, and Asia. The company is headquartered in Wülfrath, Germany.
Technologies used
RealWear Navigator 500, TeamViewer, Microsoft Teams