Industry
Automotive supplier, roof systems.
Customer story · Automotive
Webasto: high-mix roof assembly with no missed priming step.
At its roof assembly facility in Utting am Ammersee, Germany, Webasto uses Arkite to identify each product type through the PLC and guide operators through every step, with special attention for the priming sequence.
At a glance
Project summary
Process
Rooftop assembly with a wide range of variants and a critical priming sequence.
Setup
One 3D sensor and one projector.
Integration
PLC: automatic product type identification at start-up.
The challenge
Frequent changeovers and a critical priming step
Webasto's rooftop assembly covers a wide range of product variants, each with its own assembly steps. Production switches frequently between variants, which demands quick adaptation and accurate execution at every changeover.
The risk of human error was highest in critical sequences such as priming. A missed or misplaced priming operation affects the quality and safety of the finished product.
What the station had to handle
- High diversity of product variants
- High rotation between variants on the same station
- Correct sequence and location for every priming operation
- Consistent execution for new and experienced operators
The solution
The PLC defines the product, Arkite guides the operator
Webasto deployed Arkite at the rooftop assembly facility in Utting am Ammersee. At start-up, Arkite communicates with the PLC to identify and define the product type automatically. The guidance shown to the operator always matches the product on the station, without manual selection.
Arkite provides real-time guidance and monitoring for all assembly operations. Operators receive visual instructions and alerts throughout the process. The priming process receives specific attention: Arkite guides the operator through its exact sequence and locations, so no essential operation is skipped.
Implementation
How the station runs
- 01
Product identification
The PLC passes the product type to Arkite when the cycle starts.
- 02
Variant-specific guidance
Arkite loads and projects the assembly steps for that product type.
- 03
Priming guidance
The priming sequence and each location are guided step by step.
- 04
Monitoring
A 3D sensor follows execution and alerts the operator to deviations in real time.
Results
What Webasto achieved
Complete guidance of operations
Operators execute every task accurately and in the correct sequence, which reduced errors and improved consistency.
Fewer faulty finished products
Guidance through critical processes such as priming led to a notable reduction in faulty finished products.
Reduced training effort
Visual instructions enabled new operators to execute their tasks correctly sooner, with consistent performance across the workforce.
Control high-mix assembly at every changeover
See how Arkite takes the product type from your line control and guides the right steps automatically.