Rationalization and quality optimization of the commissioning process in the Rexroth plant in Elchingen


The digital assistance system ActiveAssist

Solved with

  • The digital assistance system ActiveAssist
  • Light projections and camera sensor system
  • RFID technology for assembly control

Digital assembly assistance for each product variant


Reliable commissioning

Rexroth demonstrates in-house Industry 4.0 competence with ActiveAssist. To ensure a consistently high product quality across all variants, the Elchingen plant is employing a modular, connected and interactive assistance system.

In the Elchingen plant, Rexroth produces high-quality components for mobile hydraulic applications. The assembly of up to 45 hydrostatic transmission variants takes place here. In order to rationalize and optimize the commissioning process during downstream assembly, the plant has introduced the Rexroth assembly assistance system ActiveAssist with 16 connected picking stations. The freely configurable platform offers optimal support during multi-variant assembly. It guides the employee through the work process with step-by-step instructions, ensuring flexible and cycle-time optimized commissioning.

Increased quality and shorter cycle times.

At the beginning of the process, an RFID chip on the commissioning shuttle receives the necessary order information from the production control system. The employee can then begin with equipping the four shadow boards. Light pulses at the workstations indicate which components to pick and projectors mark the correct setdown positions on the shadow boards. Mistakes are recognized by a depth camera and pointed out to the employee immediately. The project-specific Line Manager software module coordinates the individual ActiveAssists and sends the employee from one work station to the next. After commissioning has been successfully completed, the MES production control system receives a notification and all relevant information is passed on to the assembly line together with the shadow boards.