SARATROF (an acronym for System for the Analytical Assessment of Worker and Robot Aggregate Performance in Manufacturing Operations) is a research project initiated in 2021 aimed at developing a system to assess company performance through aggregated data from machines and workers. Its primary goal is to enhance production competitiveness by leveraging Information and Communication Technologies (ICT) and Artificial Intelligence (AI).
This collaborative project has been carried out in partnership with Ancora, Ledisson, Situm, and Beta Implants. It is part of the Conecta Hubs 2021 program, funded by the Galician Innovation Agency (Axencia Galega de Innovación, GAIN) and supported financially by the European Union (co-funded through the ERDF under the Operational Programme ERDF Galicia 2014–2020). Additionally, the project benefits from the support of the Second Vice-Presidency and the Department of Economy, Enterprise, and Innovation of the Xunta de Galicia.
Participation of Ancora in the SARATROF Project
Ancora’s involvement in the SARATROF project has enabled us to address and overcome several challenges outlined in our roadmap. Key achievements include:
- Design and Development of an Initial Industrial Intelligence Module
Aimed at assisting workers to enhance their productivity and efficiency. - Exploration of Additional Technologies
Ancora has experimented with new methods to improve worker competitiveness within the smart factory context, leveraging digital assistance technologies. - Analytical Techniques for Performance Pattern Identification
We studied techniques to identify performance trends over time and generate actionable insights. - Integration of Efficiency Metrics in Ancora Worker Connect
These metrics provide real-time feedback to workers regarding their performance through the platform’s interface. - Enhancing Deployment and Maintenance Processes
Improvements were made for deploying and maintaining solutions in high-availability production environments.
Progress Over the Project Timeline
- First Year:
Focused on requirement specification, use case design, and definition. Initial collaboration began with BETA Implants for deploying the Ancora Worker Connect solution at their manufacturing facility. Additionally, modules for capturing operator trace data were developed to analyze worker interactions with job orders. - Second Year:
Completed use case definitions and advanced the development of data acquisition systems. Implementation of initial analytics based on the collected data began. - Third Year:
Concluded tasks initiated in previous years, with a primary focus on the pilot deployed at BETA Implants. This pilot validated the solution in a real production environment, enabling error correction and implementation of improvements identified during operation.
The result is a more flexible, configurable, and robust platform that not only meets the specific needs of BETA Implants but is also adaptable to other industrial verticals.
Key Benefits Identified by BETA Implants During the Pilot
- Improved Access to Information:
Ancora Worker Connect (AWC) enables operators to manage tasks directly through the application, reducing the need to use a PC. This minimizes trips to the office and associated time loss. - Real-Time Production Management:
Previously, production tracking relied on paper lists updated hourly in the ERP, leading to potential errors, such as incorrect reservations or unrecorded completed tasks.
AWC significantly reduced errors during the pilot phase, with only one issue (caused by an ERP connectivity problem) compared to frequent errors before its implementation. - Enhanced Reporting and Traceability Tools:
Previously, production logs were manually recorded on paper, scanned, and archived, making access cumbersome. Now, production data is available in filterable and searchable spreadsheets.
For example, identifying potential defects in production is faster, as all related tasks, whether performed on the same machine or involving the same part code, are easily located. - Metrics for Improved Control:
Previously, one machine lacked discarded item tracking, relying solely on quality department records. AWC now enables real-time data entry during machine inspections, ensuring comprehensive tracking.
Conclusion
SARATROF has allowed Ancora to achieve the following results:
- Deliver a fully functional solution tailored to the use case presented by BETA Implants.
- Provide a solution with a measurable impact on workers’ daily tasks, improving operational efficiency and positively influencing Overall Labor Effectiveness (OLE).
- Develop metrics to quantify worker efficiency and identify deviations.
- Advance Ancora Worker Connect into a more flexible, configurable, and robust platform.