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projection work instruction

Projection work instruction as operator support system

at TNO in Leiden A new operator support system was recently integrated into a manual assembly workplace. In the demonstration cell, an operator is supported in performing tasks (work instructions) by projections.

With the help of the beamer, the correct container can be illuminated and the assembly instructions can also be projected onto the product or worktop. As a result, operators quickly know which part to pick up and where and how it should be mounted.


Operators can also receive immediate feedback if the wrong part is picked. Navigation through the work instructions is (semi-) automatic and any critical steps can be manually confirmed with the help of virtual buttons that can be projected on the worksheet.

The system can be relatively easily linked to external systems (including hand scanners, 2D / 3D vision). Production data (including processing and assembly times, quality data) are of course written into a database to enable additional analyzes.

Teach new employees

The system can be used well when training new employees, but can also be used by experienced operators when product variants and materials change more frequently.

Evaluation system

This demonstration workplace is, in connection with the TKI project Flexible Assembly (fieldlab Flexible Manufacturing), traveled to various companies. Together with these companies and their employees (operators and engineers), TNO has carried out measurements of the effectiveness and efficiency of this system compared to digital work instructions via a screen.

The effects on the employee's workload were also determined, as well as their experiences with the projection system. The results are now being processed.

The evaluation by Bas Strijker, engineering manager at Bronkhorst reads: “It was very valuable to test the OPS Light Guided System live in the factory. Within Bronkhorst, many attended the demos with our own product. All 8 operators participating in the experiment were positive. This has a positive effect. Everyone is thus able to estimate the (im) possibilities of this system. ”

Data model development

As part of the same TKI project, TNO is also developing a data model that will be linked to this OPS Light Guided System. The data model consists of a process model (including structure for process and various activities), a product model (including product description, parts, composition), a resource model (including cell, tools) and a recipe model (including ingredients, instructions).

The data model makes it possible to work recipe-driven for different product types on the basis of a production order: a process description, work instructions and configuration instructions for an assembly cell can be generated in a flexible way. The link with the OPS system means that the work instructions for an assembly activity can soon be automatically generated from the data model and presented to the system.

The results of this TKI project flexible assembly cell will be used in the 'Flexible Manufacturing Fieldlab' that will be part of the Factory of the Future program at Brainport Industries. In addition to the aforementioned organizations, more production companies, developers and suppliers of equipment and knowledge institutions are involved.


Use Case - One-piece-flow assembly line with robot vision cell

SAG Alutech Nederland BV is a specialist in the development and production of fuel tanks, hydraulic tanks and storage cabinets made of aluminum, steel and stainless steel for the commercial vehicle industry. It is a development partner for all major truck and bus manufacturers.

Their request to develop an assembly line to deliver different types of fuel tanks completely assembled and just-in-time with 100% quality control, has been worked out by us as follows:

Working together on the factory of the future

Total Productivity (TP) and TNO have maintained a pleasant working relationship for more than fifteen years, including in the Flexible Manufacturing Field Lab on the Brainport Industries Campus in Eindhoven (BIC). Here, supply and demand in the field of digital innovation and robotization are linked. The BIC is an inspiring practical environment where production companies, educational and knowledge institutions and suppliers can use each other's knowledge, possibilities and network. TP participates in the Flexible Manufacturing Field Lab with a work cell equipped with VisualFactory (VF).

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