OMNIA – Operator guidance software

The operator guidance software that simplifies manual processes, ensuring high quality and optimised execution times

Digitalization aims to make all business processes more efficient, and manual assembly is certainly a critical activity for many organizations.

From this perspective, operator guidance software provides an effective solution that assists operators and allows them to perform repetitive tasks more accurately and swiftly during a work shift.

This digital solution is intended to deliver detailed, preconfigured instructions and steps—often using graphical or text‑based user interfaces—that facilitate the execution of complex tasks or processes broken down into precise stages.

The goal of the operator guidance software is to improve the ergonomics of manual assembly or mounting phases; thus, it simplifies operations for workers on production lines, making processes rapidly executable even by less-skilled labor, while ensuring predefined quality standards.

How a digitalized workstation works

Operator guidance software OMNIA operates through an operator panel, which displays the preconfigured assembly instructions.

Depending on the specific needs of each company, the following modules may be implemented at each workstation:

Assembly Instructions
Displayed via an intuitive and user‑friendly panel, these step‑by‑step instructions help operators follow detailed guidance, minimizing errors and optimizing workflow.

Traceability
A traceability module allows monitoring of work-phase durations and component tracking—via batch numbers or serial numbers.

Tools and Equipment
OMNIA can manage a variety of tools—such as screwdrivers (including those mounted on pantographs), torque wrenches, collaborative robots, testing machines, and field sensors. It records outcomes from each device, such as torque applied or measurement values from testing equipment.

Connection Box
The Connection Box simplifies and streamlines the integration of working tools. It acts as a convergence point for operational equipment, enabling communication between the software and the operator’s tools and production-line machines.

Pick to Light
OMNIA can integrate a Pick to Light system, which uses illuminated indicators to show operators the location and quantity of items to pick, thus improving efficiency and eliminating mistakes.

Vision Box
With Vision Box, digital instructions are projected quickly and intuitively. This advanced projection system guides operators step by step, supported by a visual configurator. The integrated smart vision system enables real-time control and immediate feedback on work outcomes.

Advantages of Using OMNIA

Implementing OMNIA in a company’s digitalized workstations brings the following benefits:

Reduction of human errors
Process standardization
Simplified training
Lower training costs
Improved operational efficiency
Higher product quality
Adaptability to production changes
Effective traceability and monitoring
Use of non-specialized labor
Elimination of paper assembly instructions
Easy integration with other systems
Flexibility and scalability
Overall boost in productivity, operator performance, and assembly precision

The way the operator guidance software OMNIA validates each step can vary depending on the company’s specific needs and business rules.
To move from one operation to the next, the operator can proceed manually using a button, or delegate the process to the system, which automatically manages step advancement and/or activity locking.
Through interactive on-screen assembly instructions, the operator receives precise guidance and can be confident in correctly performing every required task.

Operation Validation

Thanks to the connection box, integrating work tools is intuitive and straightforward. This essential device serves as a convergence point for various operational equipment.
It contains a connection system that enables communication between the software, the operator’s peripherals, and the machines on the production line.

Simple, Digital, and Manual Work Instructions

To understand why it is beneficial to integrate the operator guidance software OMNIA with a Manufacturing Execution System (MES), we must first consider the relationship between MES and Lean Production, which is based on automated control and optimization to enhance business process efficiency.
In companies where production involves manual or semi-automated assembly, the data exchange between the operator guidance software and MES further improves the elimination of the seven wastes identified by the lean methodology.
This approach helps eliminate errors, increase productivity, enhance environmental sustainability, and facilitate adaptation to changing production requirements.
In essence, integrating a guided execution solution with the MES allows for the creation of a highly efficient digital system capable of effectively managing even complex production processes.

Integration of the operator guidance software with the MES

Industrial Sectors That Benefit from This Digital Solution

The operator guidance software OMNIA is ideal for companies where at least part of the production involves assembly tasks performed by human operators.
Typically, this type of digital solution is implemented in companies operating in the following sectors:

Mechanical Engineering

Electronics

Electrical Engineering

Automotive

Guided Execution workstations are generally used in manufacturing industries.

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