Modern work assistance

Industry and logistics are under massive pressure to make their processes not only more efficient, but also future-proof. In addition to global supply chain risks, high energy costs and growing competitive pressure, demographic changes are also increasingly coming into focus: while there is a shortage of qualified specialists, the average age of employees in manufacturing companies and logistics is rising continuously. According to a report by Bain & Company, the global workforce will grow by 150 million workers over the age of 55 by 2030; in many industrialized nations, this age group will make up more than a quarter of the workforce. At the same time, the retirement age is rising continuously.

Demographics as a driver for assistance technology

These changes call for a radical rethink in the design of workplaces. Automation is only part of the solution. Although age-related limitations such as reduced physical resilience or longer reaction times can have a negative impact on the ability to work, older employees often bring valuable experience and a high level of process reliability to the table. Potential that companies should actively promote. To ensure that this human factor remains productive in the future, technological support is needed that empowers rather than replaces.

This is exactly where Proglove comes in: The company is primarily known for wearable scanners and, with MAI, offers a digital work assistant that goes beyond a pure hand scanner.

From barcode scanner to work assistant

The MAI wearable companion from Proglove combines a robust touch display with haptic, acoustic and visual feedback channels, © Proglove

The development of portable scanners in the industry has so far followed a relatively linear path: Reduce weight and size, improve scanning performance. While the first generations of compact wearable scanners still focused on the basic functionality of barcode scanning (sometimes with audiovisual feedback), the integration of displays represented a real milestone: For the first time, information could be displayed directly at the workplace without employees having to turn their attention away from their immediate task.

However, MAI is not just another evolutionary stage of the hand-held scanner. The architecture differs fundamentally from previous approaches in that the system integrates several technological approaches in one: Multi-range scanners, process documentation, employee management and communication. For example, employees can use MAI to view instructions and have instructions for complex work steps shown directly on the display. This reduces errors, especially for infrequently performed or new tasks, and enables step-by-step process management, even for complex work processes. Integrated cameras and microphones can be used to record process statuses and problems in real time without interrupting the workflow. This data is fed directly into the relevant management systems and is available for further analysis.

The bidirectional communication between MAI and higher-level systems also enables the exchange of status information and instructions in real time. This creates the basis for dynamic process adjustments and makes it possible to react promptly to unplanned events. The result is greater productivity and fewer errors.

Making data usable

The Proglove Insight platform visualizes routes and process key figures in real time for the analysis and optimization of warehouse processes. © Proglove

The true strength of the assistance system therefore lies not in the hardware alone, but in its interaction with warehouse management software (WMS) systems and the cloud-based 'Insight' platform from Proglove. This is where the data collected by the wearables comes together, is analyzed and converted into specific optimization suggestions. When used correctly, the platform can identify ergonomic weaknesses as well as inefficient process patterns, recurring sources of error and bottlenecks. With these findings, workplaces can be improved in a targeted manner, ergonomic risks minimized and productivity sustainably increased.

Employees also benefit directly from these analyses: Insight can recognize, for example, when work stations repeatedly lead to long reach distances or certain work steps are associated with an above-average error rate. On this basis, adjustments can be implemented directly in the working environment. In high-frequency logistics centers, where picking times are a decisive cost factor, MAI can use the Insight platform to detect increased waiting times in certain aisles in the warehouse, for example, and redirect users to other aisles. This makes error-prone picking processes more efficient and less physically demanding at the same time.

At the same time, the assistance system remains flexible and fast. Thanks to regular software updates, new functionalities can be continuously added without having to replace hardware components.

Relieving and strengthening people

Patrick Blitz is Product Manager Shopfloor Analytics at Proglove in Munich. © Proglove

However, data-based insights alone are not enough to meet the complex requirements of the modern working world. Just as important is how this information is made available to employees at the right time and in the right place without any additional hurdles. MAI weighs just 65 g and is 21 mm high. Interaction takes place via a high-resolution touchscreen that can be operated precisely even when wearing gloves. There are also four physical buttons for fast, haptically clear operation - an important feature, especially when fine motor skills are impaired or in environments with high noise levels. The feedback channels - haptic, acoustic and visual - can also be adapted to individual needs. Employees can configure the signals according to their personal preferences, such as increasing the vibration level or amplifying acoustic signals if their hearing is impaired.

At the same time, the device can withstand industrial and logistical stresses: the robust housing is IP65-certified. The battery life is designed for continuous operation over an entire shift, so there is no need for premature recharging. Efficient energy management guarantees reliable performance even with intensive use - for example with frequent scanning or the continuous display of information.