Assembly Copilot: Revolutionizing Manual and Repetitive Assembly in the Automotive Industry

Retrocausal’s Assembly Copilot is a cutting-edge solution designed to tackle the challenges of manual and semi-automated assembly. Leveraging advanced computer vision and machine learning, this system monitors and optimizes assembly processes in real time, reducing errors and enhancing production efficiency.

Retrocausal’s Assembly Copilot delivers a host of benefits that can significantly improve automotive manufacturing:

Assembly Copilot integrates digital work instructions with poka-yoke mechanisms to ensure accuracy across various assembly tasks. Key features include:

• Live Guidance: Operators receive step-by-step instructions via screens or multimedia projectors.
• Error Prevention: The system tracks each step of the assembly process, providing audible and visual alerts to help operators avoid or correct mistakes.

Assembly Copilot automatically records cycle times, helping manufacturers to:

• Identify and Enhance: Distinguish between value-added and non-value-added work, and identify the most efficient assembly cycles.
• Benchmark and Improve: Compare different sessions, work styles, and individual assembly tasks to quickly enhance processes and overall production efficiency.

Assembly Copilot’s video traceability technology allows engineers to remotely review each step of every assembly cycle, enabling:

• In-Depth Analysis: Compare cycles across different shifts and operators to pinpoint the root cause of production issues.
• Seamless Integration: Connect with existing Manufacturing Execution Systems (MES) to store product data alongside assembly records, streamlining the identification of product batches during recall events.

Retrocausal's Assembly Copilot has already demonstrated its effectiveness in the automotive industry, including:

• Bolt Tightening Verification: Ensures all bolts are tightened correctly, addressing a common source of costly errors.
• Sub-Assembly Line Monitoring: Achieves an error capture rate of over 80% in tasks such as car door and PHEV assembly.
• Complete Vehicle Assembly: Halves line stoppages by verifying correct installation of components like windscreens.
• Operator Training: Reduces training time by 50% by serving as both a direct training tool and a proficiency assessment platform for new operators.

Deploying Assembly Copilot is straightforward. Here’s a snapshot of the process:

1. Specification: Define the Standard Operating Procedures (SOPs).
2. Capture: Record a few cycles of the assembly process.
3. Label: Annotate the video from just one cycle.
4. Deployment: Train the machine learning model.

The required setup includes a camera, computer, monitor or projector, and an internet connection. Retrocausal collaborates closely with clients to create a tailored solution that meets their unique requirements.

Retrocausal’s Assembly Copilot is a game-changer for automotive manufacturers. By reducing errors, increasing efficiency, and ensuring higher quality, it’s an indispensable tool for any manufacturer aiming to stay competitive and deliver superior products.

Ready to transform your production line? Contact our experts today to learn how Assembly Copilot can elevate your automotive operations.