How to Leverage Manufacturing Connectivity & Work Instructions

What if your work instructions could facilitate manufacturing connectivity and communicate automatically with machines and devices on the shop floor?

I/O Connect is a new VKS add-on that intelligently connects digital work instructions with machines, devices, sensors, and PLCs to create integrated workflows between people and their environments. Through this integration of pre-programmed workflows, companies gain the ability to both activate and monitor their manufacturing environment directly from their digital work instructions.

This new technology is the most recent addition to the VKS Edge IoT Suite.

• DataConnect: Communicates with databases to send and receive real-time data. Some common use cases are communicating with database-driven test equipment and label printing software.
• ToolConnect IoT: Integrates torque tools into the guided process to push Pset parameters, capture/validate torque values, and auto-advance the instructions.
• I/O Connect: Interacts with physical devices such as PLCs, pick-to-light sensors, vision systems, cobots, and integrated workflows with machines.

Award Winning Manufacturing Connectivity

I/O Connect is a new VKS add-on that is already making waves within the manufacturing Community. VKS I/O Connect won the New Product of the Year Award at The Assembly Show 2024 thanks to its ability to facilitate manufacturing connectivity and bridge the gap between people and their cyber-physical systems/machines.

By connecting directly to machines and devices on the manufacturing floor, I/O connect facilitates robust process compliance, improves quality, and achieves a new level of performance on the shop floor. It is the next step in consolidating manual and automated processes into one intelligent operation.

The integration of I/O Connect is fast and simple thanks to its reliable communication structure and its ability to perform two-way communications. Connected devices and PLCs can process the communications and feedback data directly to the worker via the VKS UI. Based on the feedback, VKS can then initiate automated processes, validate sensor readings, and automatically advance to the next step of the instructions.

Let’s go through several use cases and explore the capabilities of the software.

Use Case #1: Pick to Light System

A pick-to-light system is a smart manufacturing technology that directs users to grab the right components. Typically, a light is activated above the bin the user needs to grab a part from.

By integrating VKS and I/O Connect with Pick to Light sensors, manufacturers can simultaneously direct their workers with the right procedures while also ensuring they grab the correct parts and track material usage.

Here’s how the manufacturing connectivity integration works:

• VKS illuminates a light, indicating which part the user should pick.
• The user picks the part from the specified bin.
• VKS registers when the user picks up a part from a bin. The light above the bin flashes, indicating that the system registered the part retrieval.
• VKS automatically advances to the next step or annotation after the part has been retrieved.

This integration enhances process automation, accuracy, consistency, and control within their assembly environments.

Use Case #2: Vision Inspection System

I/O Connect enables operators to activate and monitor visual inspection systems directly from their work instruction platform. This integration enables manufacturers to streamline inspection processes and boost quality data acquisition.

In this case, I/O Connect facilitates the communication between VKS and the visual inspection tool. Once the operator places the assembled component in the inspection area, the camera is automatically activated and begins running the correct inspection process.

During the automated inspection process, VKS performs the following actions:

• Inspection Activation: VKS tells the camera what program to use and automatically takes a picture.
• Quality Validation: VKS validates with the visual system if the unit passes the inspection. If the unit passes, VKS moves to the next step. If the unit fails, VKS notifies the operator.
• Data Acquisition: VKS records and stores the inspection event (pass/fail) along with associated serial numbers in VKS for quality control and assurance.

This level of inspection system integration can also be applied to CMMs (Coordinate-Measuring Machines) and other inspection devices, ensuring that all automated inspection procedures are communicating the most accurate quality and process information.

Use Case #3: IoT Sensors & PLCs

I/O Connect enables our digital work instruction platform to communicate directly with IoT sensors. This advanced IoT integration empowers the system to autonomously gather information and validate the proper function of any automated process or environment. Similarly, VKS can also communicate with PLCs to enact various control measures for devices and machines.

Here’s how the integration works:

IoT sensors within a device, machine, or environment relay information to a VKS work instruction. At specific points within the digital instructions, VKS will request specific information from the IoT sensors. If the information is outside of proper specs or function, VKS will not allow the user to move forward with the instructions.

For example, let’s say within an electrical assembly station there is an IoT sensor that checks the temperature, humidity, and sterility of the environment. If the environment does not comply with strict standards, the assembly of the electrical components could be faulty.

During the first step of the work instruction, VKS communicates with the clean-room sensors and lets the user know if the room is currently within optimal conditions for performing the assembly work. This communication provides an automatic guarantee that components are built according to best practices and specifications.

Use Case #4: Cobot Integration

I/O Connect is able to leverage machine connectivity to send programs and activate cobots on the shop floor, providing a number of key benefits for manufacturing workflows.

• Increases error-proofing through validated process requirements, ensuring that the right program is applied to the right parts.
• Automatically capture data like process time, quality data, and sensor-based data directly from cobot and human processes.

For example, an operator is working alongside a cobot to build small microwave transformers. The worker’s task is to assemble the box and wiring and the cobot’s task is to cut the excess wire and fasten the pieces together. Once the worker has completed their tasks according to their VKS work instructions, the user can place the components into a designated area. At this point, three distinct I/O Connect actions occur.

1. VKS sends the program to the cobot and automatically advances to the next step of the process for the user.
2. The cobot either grabs the unit automatically or the user can activate the machine from their VKS interface.
3. The integrated cobot then performs its automated actions and confirms with VKS when the task is complete.

This multi-layered system will not initiate the cobot’s automated process until all conditions are met, greatly reducing the possibility of errors while increasing efficiency, safety, and quality.

Use Case #5: Machine Communications

By leveraging the machine connectivity technology, VKS can gather various data sets directly from an automated machine process while also enabling companies to control the parameters, inspection frequency, and setup of an operation.

This integration includes:

• Error-Proof Setup: Using proximity sensors along with process requirements within the work instructions, VKS will validate the data and ensure the process can move forward.
• Controlled Start: The interconnected system ensures all safety and quality procedures are accomplished before starting the machine. When combined with our Training Certification feature, only qualified personnel can open the guidebook and operate the machine.
• Cycle Count: As the automated machine completes its cycle, VKS registers and updates the cycle count to achieve live job tracking from the automated processes.
• Process Parameters: VKS measures and monitors the status of your machines, including temperature, flow rate, position, speed, and more.
• Quality Inspections: After a specific step or after a certain number of units are completed, VKS prompts the user to perform a guided inspection, guaranteeing quality control at specified intervals. Once the inspection is complete, the machine re-initiates its operation.

In the case of quality inspections, organizations can choose the intervals for their in-process quality inspections. In the visualized example below, the user is prompted to perform an inspection every six cycles.

Use Case #6: Andon Light

Companies can also use I/O Connect to integrate Andon light procedures into their workflow and increase visual cues for inspectors and team members.

For example, in-process quality inspections from a team lead or supervisor are a great way to ensure quality at the source.

However, the inspector needs to know when to come and inspect the unit and we want to remove all forms of “waiting” from the workflow.

In this case, VKS communicates with an Andon light, signaling when a worker is approaching the need for an inspection. If an inspection is needed on step 7, the Andon light can be automatically activated on step 6, giving the team lead time to see the light and make their way to the workstation.

Use Case #7: Autonomous Vehicle/Inventory Robot

VKS I/O connect also enables manufacturers to connect to a wide variety of devices and machines, including their autonomous vehicles! This level of integration enables manufacturers to have a seamless flow of material and inventory.

For example, imagine an assembly worker is building many similar units. The base components are rather large and there isn’t enough space for all the required materials. In this case, VKS automatically communicates with an autonomous vehicle to retrieve components at the specific steps the operator needs. By supplying operators with the materials they need at the moment they need them, manufacturers can clear up busy workspaces and save time retrieving parts.

Once the material has been delivered and the worker has what they need to continue their work, VKS progresses to the next step automatically.

Similarly, once a specified number of units are completed, the autonomous vehicle can be activated to grab the units and place them in inventory or prepare the units for packaging.

I/O Connect: Limitless Machine Connectivity

With its ability to communicate with PLCs and other machines based on widely used communication protocols like Modbus TCP/IP, every piece of equipment becomes a source for greater control and advanced insight.

This new level of performance opens the door to limitless possibilities for machine connectivity with your work instruction platform. By connecting directly to PLCs, machines, and devices on the manufacturing floor, I/O Connect facilitates robust process compliance, streamlined automation, quality improvements, and enhanced data collection.