Smart Workstations –
Assembly Monitoring – Real-Time Process Monitoring

An ideal Industry 5.0 assembly workstation with machine vision system and lighting combines ergonomics, intelligent assistance systems, flexible automation, and optimized lighting into a human-centric working environment.

Ergonomic workstation

• Height-adjustable worktable for seated and standing activities 
• Ergonomic arrangement of tools, monitors, and material supply 
• Glare-free working environment with optimized light distribution 

Intelligent machine vision

• High-resolution industrial cameras for quality control and process monitoring 
• AI-supported image processing for error detection, position control, and assistance functions 
• Real-time feedback for the operator via monitors or visual assistance systems 
• Documentation and traceability of inspection data 

Optimized lighting

• Flicker-free LED lighting with high homogeneity 
• High colour rendering index (e.g. Ra > 97) for precise visual inspections 
• Adjustable light colour and brightness depending on the assembly or inspection task 
• Combination of assembly lighting and illumination for industrial machine vision systems 

Human-machine collaboration

• Collaborative robots (cobots) to support repetitive or physically demanding tasks 
• The operator remains the decision-maker and quality authority 
• Assistance systems support rather than replace people 

Typical practical example

An employee performs assembly work at a height-adjustable workstation. A glare-free LED luminaire with Ra 97 and 5000 K ensures standard-compliant colour rendering and fatigue-free working conditions. At the same time, an AI-supported machine vision system monitors component positioning and detects errors in real time. The lighting automatically adapts to the respective inspection situation, while cobots supply materials or take over repetitive work steps.

In combined assembly workstations, the lighting must meet both the ergonomic requirements of the human operator and the technical requirements of industrial image processing. The human factor is always the priority, requiring glare-free, flicker-free, and high-quality illumination. At the same time, stable, diffuse, and uniform lighting conditions ensure reliable performance of the vision system. This results in a balanced solution that combines efficiency, quality, and ergonomics.

Human Factor

• glare-free lighting for comfortable working conditions 
• flicker-free illumination 
• high light quality (Ra ≥ 97) to reduce fatigue 
• uniformly illuminated assembly area 
• high illuminance of approx. 2000–3000 lx for precision assembly tasks 
• light grey housing according to DIN standards to reduce eye strain and contrast 

Industrial Image Processing Factor

• diffuse lighting to minimize shadow formation 
• evenly and brightly illuminated measurement field 
• stable lighting conditions through integrated LED current control (no brightness fluctuations) 
• defined opening or cut-out for camera integration

Furthermore, we can provide complementary lighting solutions for the Industry 5.0 workplace. These solutions not only ensure optimal lighting conditions, but also enhance ergonomics, process reliability, and efficiency within the working environment. Examples include adaptive lighting systems, status and signal lights, as well as UV and special lighting solutions for individual industrial applications.

Adaptive Lighting Systems
Intelligent lighting control for the automatic adjustment of brightness and color temperature according to the task, time of day, or individual employee requirements.
Additional focused lighting can also be activated for targeted camera inspections and vision-based quality control.

Status and Signal Lights
Visual LED signals for the clear display of machine conditions, process sequences, or safety information in real time.
They can also serve as indicators for time-sensitive visual inspections or assembly stops.

UV or Specialized Lighting
Specialized lighting solutions for applications such as material inspection, fluorescence analysis, or controlled cleanroom environments.

Until now, it has often been common to check the work step only after completion at another location. Assemblies often need to be time-consuming sorted out or reworked.

With real-time monitoring, errors are detected directly during the work step and communicated to the worker. This allows the worker to correct the error immediately and with minimal time investment.

The worker learns instantly and can avoid making the same mistake when assembling the next assembly.

When a part or assembly is positioned at the workstation, it is automatically recognized using:

• Its shape
• Features
• QR codes, barcodes
• Labels

This prevents component mix-ups, or the worker receives additional information such as work instructions for the product.

For a thorough incoming goods inspection, packing lists, delivery notes, and carrier handover protocols are typically checked. Additionally, the goods are inspected for accuracy, defects, and quantity.

This process can be significantly improved through a smart workstation.

After scanning, the employee receives additional important information about the order, the product, and the inspection criteria.

Furthermore, photos can be added for documentation purposes.

An important part of outgoing goods is the outgoing goods inspection. This checks whether all goods are complete, properly packaged, and free from defects.

After scanning, the employee receives additional important information about the order, the product, and the scope of delivery.

Since this is done digitally, fewer paper documents are required, helping to avoid mix-ups.

Furthermore, photos can be added for documentation purposes.

Optical quality inspection refers to various testing methods for determining and ensuring the quality of products from production. For example, the quantity of components can be determined, as well as their dimensions, the quality of laser markings, or the surface condition.

This process can be enhanced or supported by industrial image processing. The camera has neither fatigue nor off days.

Especially in this area, it is crucial that both the worker and the camera system are equipped with optimized lighting for both.

Manual assembly carries a high risk of errors when no worker guidance system is in place. Clear instructions or a worker assistance system are therefore essential to reduce the likelihood of human errors.

These systems provide support through:

• Digital work instructions
• Real-time feedback on potential errors
• Easier and faster onboarding of new employees
• Another advantage is the easier adaptation to frequently changing assemblies.

The ability to design more flexible work assignments increases employee satisfaction, as the support from the employer creates a sense of security at work.

Assistance robots, i.e., robots that share the workspace with humans, enable partial automation of assembly tasks. This allows work steps that are not economically suitable for full automation to be automated.

To interact safely and meaningfully in the human workspace, assistance robots must meet several requirements:

The demands on assistance robots are diverse. The focus is on:

• The safety of the worker
• Easy operation to allow flexible deployment of employees
• Additionally, robust process execution must ensure seamless integration into the previously manual assembly environment.

When developing assistance systems, appropriate lighting to detect potential risks is crucial. At the same time, a pleasant lighting environment must be ensured at the workstation.