Shopfloor: Work Instructions and Fault Resolution Directly at the Machine

A manufacturing company with 350 employees produces variant-rich components for the automotive industry across 5 production lines. Each line operates with detailed work instructions, inspection plans, safety procedures, and fault resolution guides. These documents lived in paper binders at the line — outdated, hard to find, circulating in different versions.

When an error code appeared or an unfamiliar situation arose, workers had to call the shift supervisor, search binders, or phone the production office. The line often stood still in the meantime.

Delivering Knowledge Without Delay to the Right Place

The problem is not a lack of information — the documents exist. The problem is accessibility at the right moment, in the right place, for the right person.

Local Shopfloor Assistant with SoverIQ Box

SoverIQ Box — a ruggedised edge device — is mounted at each production line. All work instructions, inspection plans, safety data sheets, and fault diagnosis trees are indexed locally — always current, centrally maintained:

• Workers type or speak their question: “How do I set up the line for variant B37?”
• System shows the current work instruction with step-by-step photos and videos
• Error codes are automatically recognised (PLC interface) and answered with diagnostic steps
• Safety instructions appear contextually: “Caution: PPE Level 3 required for this step”
• New employees receive guided instructions in their native language (DE/EN/TR/RO)

No internet connection needed. No paper binders.

Results

Unplanned line stoppages due to uncertainty or misinformation fell by 44%. Induction time for new employees cut from 10 to 5 weeks. Error rate from incorrectly applied work instructions fell by 31%. Shift supervisors are interrupted less often for routine questions — and can focus on leadership tasks.