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Digitalization turns knowledge into efficiency
Innovation occurs when theoretical knowledge is translated into practical applications. The XRAP research project is developing a digital assistant that will revolutionize industrial setup processes by combining XR and AI. The following functionality is planned: An employee holds a tablet in their hand. The tablet highlights in color which components are required for the next step in the setup process. The XR glasses are then put on and a detailed virtual display appears directly in the employee’s field of vision, showing where a part needs to be fitted. In addition, further information on the current work step and component can be added, e.g. from an operating instruction. At the end, employees receive feedback on whether the parts have been installed correctly or whether any reworking is required. The digital assistant guides them step by step through the entire set-up process and enables errors to be identified and rectified at an early stage. The XRAP project aims to bring this future scenario one step closer and thus revolutionize the current status quo in set-up processes.

XRAP: The digital assistant for error-free set-up
In January 2025, the joint project “XR Assistant for Setup Processes in Production” (XRAP) was launched as part of the “Future of Value Creation – Research on Production, Services and Work” funding measure of the “Future of Value Creation” program of the Federal Ministry of Education and Research (BMBF). The project is scheduled to run for two and a half years and aims to develop a digital, XR-based assistant to support the setup of machines. One of the use cases for this project is set-up processes in the compounding or extrusion of plastics. The low-code platform from Simplifier AG serves as the technological basis for the development of the application. XRify GmbH is contributing its expertise in XR – particularly with regard to interaction with the user. The SKZ is responsible for the process analysis, requirements definition and development of the AI. By combining XR technology and AI, the digital assistant developed as part of the research project will be able to monitor the setup process and provide support in real time. This will prevent errors and save time.

Understanding processes is a key factor in digitalization
Understanding setup processes is crucial to the success of a project. The digitalization of these processes requires an in-depth technical understanding of the processes as well as precisely defined requirements for the development of the digital assistant. With its close ties to the plastics industry, SKZ has extensive knowledge of set-up processes and understands the specific challenges that employees are confronted with here. On the one hand, this process knowledge enables the targeted development of the assistant’s AI-supported object recognition. On the other hand, it is crucial for tailoring the XR system to the needs of the employees. To this end, XRify contributes its experience from the application of XR-supported processes in industry. Only when relevant information is available at the right time and in the right place can real added value be created for companies and their employees. The results of the research project are not limited to the plastics industry, but can be transferred to all other industries thanks to the flexible structure of the software designed by Simplifier. The AI-based setup assistant supports skilled workers directly on site, reduces errors and speeds up processes – a decisive step towards intelligent and digitally networked production in Industry 4.0.

This project is funded by the Federal Ministry of Education and Research in the Future of Value Creation research program under the reference 02K24K012.