Collaborative Workbenches

The aim of the collaborative workbench was to:

• Reduce the learning curves associated with product change
• Allow information to be consumed in a modern manner
• Accommodate a more transient workforce and support operations with greater flexibility
• Create standard processes and put greater emphasis on the manufacturing engineering content produced

Producing Innovation

The prototype was revealed at the Farnborough International Airshow 2018 and received interest both internally within BAE Systems and from external organisations. Following this success, BAE Systems approached Fairfield Controls Systems (FCS) with the requirement to take the design from a prototype workbench to a workbench which could be delivered into a production environment. This project had several challenges, including:

• Producing an innovative product using the latest Industry 4.0 technologies whilst working within BAE standards and specifications
• Producing a workbench suitable for BAE systems operational procedures with future scalability
• Design, build and put into operation a solution within 6 months to meet the production schedule
• Integrate the workbenches into BAE Systems existing Enterprise Resource Planning (ERP) system and network infrastructure

Ergonomics and Comfort

FCS designed a workbench that allows the user to adjust height and lighting levels to suit their personal preferences. These settings can be saved and later reloaded using an RFID identity card, which automatically configures the workbench when the user logs on.

This improves ergonomics and comfort for users who are required to stand, orientate and work on a wide range of complex parts. These parts vary in shape and size and are often made up of multiple components.

Once logged on, the user receives work instructions issued from the BAE Systems SAP system. These instructions provide step-by-step guidance to complete each work package.

As the user progresses through the instructions, an optical projection system highlights specific areas of the work package relevant to the current step. In addition, an automated vision system periodically verifies that each instruction has been completed correctly before the user proceeds.

SAP System Interface

The workbench includes a SAP client through which work instructions are delivered. As the user works through each task, images, instructions and guides are projected onto the workpiece to support the SAP client interface.

For security and confidentiality reasons, the Collaborative Workbenches do not store complete product data locally. Instead, a broker acts as a gateway between the SAP server and the workbenches.

When a projection or verification step is required, the SAP server sends the relevant file to the broker. The broker then distributes it to the appropriate workbench.

Once used, projection and verification files are deleted. This approach ensures that sensitive data is not stored insecurely. It also allows work instructions to be updated within the SAP system while maintaining a fully configuration-controlled environment.

Projection System

The workbenches make use of 3D optical projection technology. The system uses Augmented Reality through a hardware and software system. This imports existing and/or creates new 3D geometry, taken directly from CAD to project simple yet concise work instructions onto contoured surfaces to solve complex assembly tasks.

Verification System

The workbench includes a vision system which is used to verify that each assembly task has been carried out correctly. As part of the user’s work instructions, there are steps for verification. When the user reaches a verification step, the workbench lighting is automatically optimised for the visual inspection and then a smart camera analyses the work package. The work package is compared with verification files issued by the SAP system and the user is presented with a Pass or Fail indicator. The user can then review the image.