Laser-based worker guidance systems can increase precision, efficiency, and process reliability in manual THT assembly by providing standardized visual work instructions. At Siemens in Fürth, the solution “Der Schlaue Klaus” from Optimum datamanagement solutions GmbH is used for this purpose, leveraging the compact and cost-effective ZLP1 laser projector for visual worker guidance. This article explains how laser projection supports low-error, repeatable execution of manual work steps and shows how the Z-LASER ZLP1 visually guides manual THT assembly within this worker guidance system.
Real-Time Visual Guidance: Z-LASER ZLP1 for Worker Guidance
The ZLP1 is a compact laser projector designed for short distances and small working areas, making it ideal for manual workstations. Used for visual worker guidance, it projects work instructions directly onto the work surface and guides operators step by step through the assembly process. This helps ensure that each work step can be carried out correctly and with consistent results. The number of projections can be adapted to the complexity of each work step. The ZLP1 can project multiple markings or contours simultaneously. This supports more efficient execution of both simple and complex manual assembly workflows.
The compact ZLP1 is also used at manual workstations at Z-LASER. Here, it supports our employees during the production of new ZLP1 projectors.
Simple Installation and Modular Expandability
Thanks to its compact design, the ZLP1 can be installed easily at manual workstations and aligned flexibly. Using a swivel and tilt ball head mount, the laser projector can be mounted to aluminum profiles or installed on the ceiling. The ZLP1 can also be expanded with additional components with minimal effort. These include a barcode scanner to identify components and orders, a foot switch to confirm work steps, and other control elements required to adapt worker guidance to existing workflows and requirements.
Software-Controlled Laser Projection with ZLP Manager
Combined with the ZLP Manager projection software, the system can project not only contours but also images, text, or process steps at defined positions. Path-optimized fonts help ensure highly stable projections. This gives operators a clear overview of the production process at all times.
Optional API Integration
The Z-LASER ZLP1 can be integrated via API into existing process and software environments, enabling direct control from existing systems.
Practical Example: “Der Schlaue Klaus” at Siemens in Fürth
A practical example of the value of visual worker guidance via laser projection in manual assembly workflows is the use of the Z-LASER ZLP1 within the worker guidance system “Der Schlaue Klaus” at Siemens in Fürth. Integrated into a production line, “Der Schlaue Klaus” guides operators step by step through the assembly process. The ZLP1 used in the system projects the relevant insertion position directly onto the printed circuit board (PCB) and removes the marking again after correct assembly. In addition, a monitor provides process-related instructions. In this way, THT assembly can be carried out reliably even with a high mix of variants.
Z-LASER ZLP1: Compact Laser Projector for Efficient Worker Guidance
ZLP1 – Laser Projector
The ZLP1 is a compact and cost-effective laser projector designed for industrial applications. It is particularly suited for small working areas and short distances, making it ideal for picking, logistics, and worker guidance tasks. By projecting optical work instructions directly onto the workspace, the ZLP1 supports employees in real time, increasing both efficiency and process reliability. The projector is eye-safe in laser class 2M and can be controlled via the intuitive ZLP-Suite software or integrated into existing applications through an API. Additional software modules allow flexible function extensions, ensuring the ZLP1 can be adapted precisely to individual requirements.
Learn MoreConclusion: Optimized Manual Assembly Workflows Through Laser-Based Guidance
The use of the Z-LASER ZLP1 in the worker guidance system “Der Schlaue Klaus” demonstrates how laser-based worker guidance can optimize manual production workflows. Visual work instructions make process logic directly visible in the work area and guide employees step by step through the process. This standardizes assembly and supports consistent process quality. This is relevant not only for process-critical manual THT assembly but also in production environments where automatic THT assembly and manual assembly interact.
Want to take the efficiency and reliability of your assembly processes to the next level? Contact us for a personal consultation. We will be happy to advise you on the right worker guidance solution for your application.
Frequently Asked Questions
A worker guidance system supports manual assembly processes with visual work instructions. Systems such as “Der Schlaue Klaus” project these instructions directly onto the work surface via the Z-LASER ZLP1 to standardize work steps and support consistent process quality.
In THT assembly, the ZLP1 projects markings and work instructions directly onto the PCB, so the insertion position is clearly visible to the operator. This supports standardized, low-error execution.
Yes. A worker guidance system using the Z-LASER ZLP1 can be expanded with additional components such as barcode scanners to identify orders or foot switches to confirm work steps.
One example is Siemens in Fürth. There, the worker guidance system is integrated into a production line to support employees during manual THT assembly.
