Operator Assistance for Quality-Critical Manufacturing

Error-Free Production, Starting on Day One

The PGX operator assistance system guides your employees step by step through every production process. Less rework, shorter training, and complete documentation. Manufacturer-independent and ready for use in just a few weeks.

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✓No obligation
✓Use existing hardware
✓Seamless integration

> €500,000 saved on a client project

WHY PGX

Six results you’ll see starting in week one

Prevent Errors Before They Occur

PGX guides employees step by step through the process. Rework, scrap, and customer complaints decrease measurably.

Productive in Hours, Not Weeks

Visual guidance reduces training time and makes knowledge immediately available. New employees can get started the very same day.

Document every step in an audit-proof manner

All process data is automatically recorded. Audits and liability issues can be documented at any time.

Maintaining Quality Despite a Wide Range of Variants

PGX standardizes processes even with a large number of variants and ensures consistent results.

Remain independent of manufacturers

PGX is vendor-independent and integrates with existing tooling, MES, and IT systems.

Create Work Instructions in Seconds

PGX Q·AI automatically converts Word, PowerPoint, and PDF files into structured digital instructions.

Case Study · STAHLWILLE

> €500,000

saved for a customer through reduced rework, shorter training times, and more stable processes. In collaboration with our partner STAHLWILLE.

Alexander GrosserSTAHLWILLE Eduard Wille GmbH & Co. KG

▶Watch the testimonial video

Where the savings come from

Rework & Scrap
-75%

Training time
-80%

Time spent on audit documentation
minutes instead of hours

A Look at the Software

This is what worker guidance with PGX looks like on the job

Work Plan Overview

A complete overview of all orders and work plans, including status by station.

Work Planning

Create work plans, maintain variants, and centrally provide specifications.

Steps

Images and annotations guide you through each step, and results are documented along the way.

Connected Operator Front End

Guide. Execute. Empower.

A frontend for everything that happens on the job. PGX guides employees safely through assembly, inspection, rework, and service, and actively controls processes via machine connectivity and IoT directly on the shop floor.

Work instructions, inspection steps, tool parameters, measurement results, error patterns, and documentation are all available in a single interface. No need to switch to a second system, no searching through paper documents, no media discontinuity.

The Guided Beat

Identify the order and variant

A scan or MES trigger loads the appropriate work plan.

Visually Specify the Step

Image, marker, and preset value at the workstation.

Configure and approve the tool

Torque, program, and lock are derived from the process.

Check and document the result

"OK" or "Not OK" determines whether the part is approved or requires rework.

CSP Manufacturing OS

PGX is the execution layer in the CSP Manufacturing OS

You start with operator guidance and grow into the same platform: same database, no second integration.

AI Use Cases & Benefits

APC Analytics &Reporting: Making Data Visible in the Process

DPP & DigitalTwin: Digitally mapping products and processes

Closed QualityLoop: Addressing Deviations Directly

PredictiveQuality: Identify risks early, prevent downtime

Manufacturing OS

CHRONOS IoTData: Production and quality data

IoT DataHub: Consolidate data

Integrate MCPKI with production data

Archiving: Long-term storage

Connectivity & IoT Gateway (IPM) Connect. Collect. Orchestrate.
Capture and distribute data in real time

Connected Operator & Job Execution (PGX)

Guide. Execute. Empower.
Operator front end, visual guidance, execution

Process Capability Inspection (QST) Test. Inspect. Assure.
In-process testing and quality assurance

Shop Floor & Data

Protocols: IPM Real-Time Protocol · OPC UA · S7 · Modbus · XML · REST · MQTT · Open Protocol · …

Machines & Stations

Control Systems & PLCs

Sensors & Devices

Measuring Instruments

and more

PGX Q·AI

Turning PDF chaos into a clean SOP

Upload existing documents and receive structured work instructions—without having to overhaul your document management system.

WORKER MAX Every day, new PDFs and Word files pile up. How am I supposed to turn them into organized work instructions?

PGX Q·AI It’s simple: just upload them, and I’ll take care of the rest.

WORKER MAX Really? Completely automatically?

PGX Q·AI Sure. I’ll organize everything into a consistent, error-free SOP in seconds.

up to 100 % documented process reliability Every step traceable, even years later in an audit.

up to 80 % faster onboarding New employees contribute from day one.

up to 75 % less rework
Defects are prevented instead of fixed later.

Frequently Asked Questions

What is a worker assistance system? A worker assistance system handles digital worker guidance: It guides employees through each step of the process, verifies that the steps are performed correctly, and automatically documents them. Instead of paper instructions, workers see exactly which step is next.

How much does a digital worker guidance system cost?

The cost depends on the number of workstations and the desired level of integration. You can start with a single line, and existing hardware can continue to be used. During the initial consultation, we’ll provide a reliable estimate for your specific use case.

With which manufacturers is the PGX worker assistance system compatible?

PGX is completely manufacturer-independent and compatible with, among others, Atlas Copco, Desoutter, Cleco, Gedore, Bosch Rexroth, Stahlwille, ELIAS, ITH, HST, Keyence, Hytorc, MB-RAD, Ingersoll Rand, Sturtevant Richmont, AcraDyne, and Stanley.

Is a worker assistance system subject to legal requirements? Comprehensive documentation is crucial for product liability, traceability, and standards such as ISO 9001 or IATF 16949. PGX generates this documentation automatically, without any additional documentation effort.

For which industries is digital worker guidance suitable? For all industries with complex, quality-critical processes: automotive, mechanical and plant engineering, aerospace, rail, medical technology, and series and variant production.