ABSTRACT

AUGMENTED REALITY FOR OPERATORS TRAINING IN COMPLEX MACHINERY SETUP

The Merano Plant is part of MEMC Electronic Materials SpA, which is part of the GlobalWafers group, the third largest producer of silicon wafers for electronics in the world.
In Merano, the silicon crystals are produced and then sent mainly to the other Italian plant in Novara which will produce and sell the silicon wafers. 
The proposed "testimony” aims to present a collaborative project between the Merano plant and the University of Bolzano.
The project is focused on providing training modules, based on Augmented Reality (AR) technology and Visual Management (VM) techniques, to operators responsible for the equipment setup. 
The setup procedures for Si crystal grooving machines (Pullers) require precise sequences, operations, and precautions during the assembly of approximately one hundred high-purity quartz and graphite pieces. 
The pullers have variable cycle times of several weeks, with consequently reduced training access opportunity.
This training period has a range from 3 to 6 months due to practical organizational challenges (such as requiring a trainer’s presence when machines complete their cycles and when trainees are available during shifts). 
The purpose of this work is design and implement a training center separate from the production areas. the operator can practice using a mock-up of the machine and setup parts with the help of AR and VM techniques, ultimately maximizing visual support effectiveness. 
Based on the training and company needs analysis, the project was divided into three phases:
1)  development, implementation, and validation of a VMAR-type training module for newly hired/inexperienced operators to promote efficiency, speed and robustness of the learning process,
2) development, implementation, and validation of a training module for trainers that allows the creation of the technical and pedagogical skills necessary to effectively use the VMAR tools for training
3) conceptualization and design of the training center in terms of furniture tools and layout.
At the same time, an analysis of the cost/benefit ratio was conducted based on the results of tests appropriately designed and conducted in phase 1.
 
We are in P. 2, involving operators and trainers we have carried out targeted tests whose very positive results would be part of the presentation.
We are entering P. 3 and we aim to create two training stations for two different types of pullers. 
The project’s primary target is to reduce the training duration for new hires from 3..6 months down to 3.. 6 weeks. Additionally secondary target is to facilitate learning for non-native peoples who face objective difficulties in reading written procedure. 
The Apps necessary for AR were developed by a graduate student from Bolzano Uni., using Microsoft glasses and "Unity”  as development environment.
From Q3 2024 we will use this method in production which we believe is interesting to share with those who have similar needs which require assembly sequences of expensive complex parts, and which if carried out incorrectly, causes serious malfunctions of the machine and   production losses.
In our case, the value of the set-up components is approx..  100 kEuro with even higher impacts in the event of loss of a production batch.
 
The presentation aims to highlight two aspects, the technology itself and the importance of a collaborative relationship between companies, universities, and research institutions.