Step-by-step work instructions that verify every action before release.
FlexIPS guides operators through complex assembly, loads the correct variant instructions, verifies each step with cameras, scanners, PLC signals, and tools, then records the evidence against the serial.
0 skipped steps
gated sequence prevents accidental advance
High-mix ready
recipes load by serial, barcode, or MES
Full evidence
images, values, users, and verdicts stored
Step 1 of 4
Identify serial and variant
The station reads the serial or receives the order, then loads the correct recipe, images, limits, and instruction flow.
Vision check
Tool value
Operators get the next correct action. The station checks the result.
Paper instructions tell people what should happen. FlexIPS turns the work instruction into an enforced production workflow: the right variant, the right sequence, the right verification, and the right trace record.
- Reduce skipped steps, wrong sequence builds, and undocumented manual decisions
- Accelerate high-mix changeovers by loading the correct recipe from serial, barcode, or MES
- Capture proof for every critical operation without adding paper checks
- Shorten training time for new operators and temporary production support
- Route failed steps to FlexCheck with the image, reason, and next action already attached
Digital work instruction
Transmission case - Variant X1
Built for real station control, not static instruction screens.
Step-gated work instructions
Break complex builds into controlled steps. FlexIPS only unlocks the next instruction after the required scan, image check, tool value, or operator confirmation is complete.
Projection and visual cues
Show the next placement, fastening sequence, connector path, or inspection zone directly on the fixture with FlexProjector or on the station screen.
Torque and tool capture
Connect DC screwdrivers, torque tools, press controllers, or sensors so manual assembly steps are validated against the exact recipe limit.
Vision verification per step
Confirm presence, orientation, seating, routing, label read, connector lock, and other visual checkpoints before the operator can continue.
Training and skill control
Give new operators a clear build path and restrict critical actions to approved users, while supervisors can review controlled overrides.
FlexDashboard evidence
Search any serial to see the active recipe, completed steps, operator actions, tool values, images, failure reasons, and final release decision.
From serial scan to verified release in one controlled cycle.
Step 1
Identify serial and variant
The station reads the serial or receives the order, then loads the correct recipe, images, limits, and instruction flow.
Step 2
Guide the next action
Operators see the exact part, orientation, tool, and action for the current build step, with optional projection onto the fixture.
Step 3
Verify before advancing
Cameras, scanners, PLC signals, and torque tools confirm the step. A failed check blocks the next step and gives rework guidance.
Step 4
Record the evidence
Every confirmation, image, torque value, override, and verdict is written to the unit history for FlexDashboard and MES.
Sensor plug not fully locked
Captured confidence 0.61, required 0.90. Re-seat connector and retry.
A wrong action becomes immediate feedback, not an escape.
If a scan does not match, a part is missing, a connector is not locked, or a torque value is outside tolerance, FlexIPS holds the station and shows the exact failed step. Operators get a clear recovery path while quality gets a complete record of the exception.
- Station lock on missing data, failed images, wrong variant, or tool values outside limits
- Rework, retry, and controlled supervisor override flows
- Reference overlay and captured image attached to the failed step
- Every exception tied to user, timestamp, recipe, station, and serial
Every instruction becomes part of the unit history.
FlexIPS records what the operator was asked to do, which checks were required, what actually happened, and why the unit was released or held. That turns operator guidance into audit-ready production evidence.
Recipe proof
Variant, instruction version, limits, image references, tool targets, and active station context.
Step proof
Pass/fail state, images, scan payloads, confirmations, torque values, and PLC handshakes.
Decision proof
Operator, timestamp, retry count, rework outcome, override reason, and final release verdict.
Guidance connected to the station, tools, and data systems.
FlexIPS fits around the production line you already have, from simple sensor handshakes to full MES recipe and genealogy integration.
Station and PLC control
Trigger from part-present, recipe-ready, clamp status, and release signals. Return PASS, FAIL, hold, and rework state to the line.
Tools and inspection devices
Use live values from cameras, scanners, torque tools, press controllers, scales, sensors, and barcode readers as step acceptance criteria.
MES and quality systems
Load work orders and recipes from MES, then write step results, serial history, images, overrides, and final verdicts back to your data model.
Operator guidance is strongest when it is tied to inspection and traceability.
Use the same FlexIPS station layer to guide work, verify the result, and keep the production record complete across related workflows.
Assembly Verification
Step-gated assembly with torque capture, vision checks, and serialized build evidence.
Screw Tightening
Guide screw position and sequence while capturing torque, angle, and machine-vision proof.
Wiring Harness
Guide connector placement, wire routing, clip seating, and variant-specific board layouts.
Traceability
Tie every guided action, captured image, and operator decision to a searchable serial record.
Common questions from production, quality, and process engineering teams.
How FlexIPS turns work instructions into verified station workflows with projection, tool capture, traceability, and fail handling.
What is digital operator guidance?
Digital operator guidance replaces paper instructions with a controlled, step-by-step station flow. FlexIPS shows the next action, loads the correct recipe for the serial or variant, checks the action with cameras, scanners, tools, or PLC signals, and only advances when the step is complete.
How does FlexIPS prevent skipped assembly steps?
Each instruction can be gated by a required verification: barcode read, camera check, torque value, tool signal, operator confirmation, or PLC handshake. If the required condition is missing or outside tolerance, the station holds and the next step remains locked.
Can operator guidance handle high-mix production?
Yes. Recipes, part images, torque limits, projections, inspection zones, and acceptance rules can be loaded by barcode, serial, work order, or MES data. One station can switch variants without paper changeover, while each unit is verified against its own flow.
Does it support projected work instructions?
Yes. FlexProjector can project the next part position, connector path, fastening sequence, or inspection zone directly onto the fixture. The operator gets a physical cue at the work area, and FlexIPS can still verify the result with camera and tool data.
What happens when an operator makes a mistake?
The step fails immediately, the unit is held, and FlexIPS shows the failed region or value with a clear action such as rework, retry, or supervisor review. The failed image, reason, user, timestamp, and final decision are stored against the serial.
Can guidance data be traced for audits?
Yes. FlexIPS stores the active recipe, each step result, operator confirmations, scans, captured images, torque and process values, failures, overrides, and final verdict. FlexDashboard can search the serial and export the evidence package for audits or customer claims.
How does FlexIPS integrate with existing stations?
FlexIPS can run as a station guidance layer connected to PLC I/O, OPC UA, SQL, REST APIs, scanners, cameras, and torque controllers. It can load recipes from your systems, drive the operator workflow, and return pass/fail or traceability data without forcing a full line rebuild.
Have a question we didn't answer? Request a demo and we'll map it to your line.
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Turn one work instruction into a guided station demo
Share a sample assembly flow, defect mode, or current paper instruction. We will map the guided steps, verification gates, fail handling, and traceability record around your station.