Paperless assembly

Optimization and automation of manufacturing processes

The challenge

At ROMA KG, a constant focus is placed upon optimizing and automating manufacturing processes. The lines for the individual production steps are computer-controlled and thus precisely aligned to each other. It did not appear appropriate given this background that a printed docket had to be used for each production order. Only in this way could the order-related information be transmitted to the employees at the individual assembly stations.


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How we helped

Under the motto “Paperless Assembly”, the task for the XITASO experts was to develop a software solution with which the paper-form dockets can be dispensed with. The focus should therefore be on a web application that runs on a central web server in the main plant. From there, small tablet PCs should be operated, which are attached to the individual assembly stations in the various plants. The reason for choosing a browser application was that the choice of tablet PCs is not tied to a particular make and thus offers a high degree of flexibility.


HTML5 AngularJS Communication between AngularJS and PLC

Order-specific data and additional information, context-related, at all assembly sites thanks to a high-performance web application

Saving hundreds of thousands of sheets of paper and valuable time through digitization

Interface between ERP database and PLCs of production facilities

Generation of consistent production data for quality assurance and process improvement

For the definition of the information to be displayed on a particular job at a particular assembly site, separate table formats are introduced in a restricted area of the database of the existing ERP system. This ensures that ROMA KG’s IT department can maintain similar workflows to take advantage of the dispersing of generic content from the ERP system.

Since you were no longer bound to the paper form, additional documents can be added to an order. Additional information such as bills of materials/parts lists, work instructions, and operating instructions for third-party components are provided in context.

Furthermore, a database-based labelling of whether a possible basis for rework has been identified allows evaluations that can be used for quality assurance or can form the basis for further process optimizations.

The order-related information is retrieved by default by reading a barcode with a handheld scanner. In a second phase of the project, the “paperless assembly” was further developed and supplemented by a PLC component. This makes it possible to communicate directly with the control of the conveyor system, which has enabled workplaces to be created on a new fully automated conveyor system. Thus, the “paperless assembly” on this conveyor system serves on the one hand as an elegant user interface and on the other hand it has a supporting interface function between order-related information from the ERP database and the system control.

Other projects

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Dr. Michael Schackert

Phone +49 821 885882-36