Application
Assembly Guidance & Verification for Ajusa
Real-time AI guidance for assembly operators. Catch errors before they happen. 98% accuracy, 35% faster assembly, zero defects reaching customers.
98%
Assembly Error Detection
35%
Faster Assembly Time
0
Field Defects from Assembly Errors
The Challenge
Manual assembly is error-prone, slow, and inconsistent. Operators rely on memory, printed work instructions, and supervisor oversight—all prone to failure.
😞
Operator Fatigue
Assembly is repetitive. Operators tire after 6-8 hours. Error rates spike at end of shift.
📋
Paper-Based Work Instructions
Printed SOPs are outdated, hard to follow, don’t show what’s correct. Operators interpret differently.
❌
Post-Assembly Rework
Errors caught after assembly. Rework is 3-5x slower than getting it right first time. Scrap costs add up.
🚚
Field Failures
Assembly errors reach customers. Recalls, warranty claims, brand damage.
How It Works
Real-Time AI Copilot for Assembly
👁️
Live Operator Guidance — Tablet or HUD shows exact next step with photos/video
🚨
Instant Error Detection — AI catches skipped steps, wrong components, misalignment in real-time
✅
One-Click Verification — Operator snaps photo. AI approves or flags for correction.
📊
Operator Learning — AI learns from each operator’s mistakes. Coaching improves over time.
🤖
Assembly Guidance in Action
Real-time assembly guidance system — AI guides operators through each step and verifies accuracy in real-time
Key Features
📱 Mobile Guidance
Tablet or smartphone displays step-by-step instructions with photos, videos, and diagrams
🔍 Vision Verification
Operator takes photo. AI verifies assembly is correct before moving to next step.
🚨 Real-Time Alerts
Instant notification if operator skips steps or uses wrong component
👤 Operator ID Tracking
Know who built what. Quality metrics per operator. Identify training gaps.
📊 Real-Time Dashboard
Supervisors see assembly progress, error rates, time per unit on live dashboard
📈 Performance Analytics
Identify slowdowns, bottlenecks, and training opportunities. Optimize assembly sequence.
Proven Results
98%
Assembly Error Detection
Catches skipped steps, wrong parts, misalignment. Zero escapes to customer.
35%
Faster Assembly
No searching for instructions, no supervisor questions. Guided workflow speeds up process.
€45k
Annual Savings per Line
Reduced rework (€28k) + prevented recalls (€17k) = significant ROI.
3.5
Weeks to ROI
System pays for itself in less than a month of operation.
Test AI Assembly Guidance on Your Line
We’ll train the AI on your assembly process and run a 5-day POC. See real results with your operators and products.
Request Free POC →FAQ
How long does it take to train the AI on our assembly process?▼
We capture 10-15 “gold standard” assemblies (done correctly by expert). AI learns from those videos. Training takes 3-5 days. Then we run a 5-day POC on your line to optimize detection and reduce false positives. Full deployment: 2-3 weeks.
Do operators need to learn new software?▼
No. The interface is designed to be intuitive—most operators get it in 30 minutes of hands-on training. It’s like using Instagram: swipe through steps, tap to take a photo, AI approves or gives feedback. Training reduces after day 3.
What if the AI makes mistakes?▼
AI is supervised. Supervisors can override if needed (“this is OK, mark as complete”). Each override trains the AI. Miss rate drops to <1% after 2 weeks as the AI learns your specific requirements and edge cases.
Can you handle complex assemblies (20+ steps, many components)?▼
Yes. We’ve deployed on assemblies with 30+ steps and 50+ components. AI handles multi-step verification, component orientation, torque (if camera-detectable), and sequential logic (e.g., “Step 5 only valid if Step 3 passed”).
What’s the cost for a 5-operator line?▼
€3,500/month (hardware + AI + support). Includes 5 tablets/cameras, AI training, supervised rollout, and performance monitoring. Most customers see ROI in 6-8 weeks through reduced rework and faster cycle time.