Self-optimizing assistance system for AR-assisted machine changeover




  • Smaller production batches, due to product customization, and the increasing format flexibility of machines and plants lead to an increasing number of format changes
  • Long startup phase until optimum operation following format changes
  • Differing experience and process knowledge of the setup personnel

Research results

  • Assistance system for the setup process for production plants
  • Visualization of assistance information using Augmented Reality (AR)
  • Knowledge building blocks such as text, images, and videos coupled with semantics for the preparation of AR contents
  • Calculation of process parameters for an optimized startup phase via machine learning (ML)


  • Easy preparation of setup instructions without having special IT knowledge for AR applications
  • Support for setup personnel via the preparation of location-relevant information
  • Higher overall equipment efficiency (OEE)
  • Fewer product rejects due to a short startup phase
Logo of the BMBF
Federal Ministry of Education and Research

AR-assisted support for setup processes


The coSAM project is developing a self-optimizing assistance system for Augmented Reality (AR) assisted machine setup. The availability of relevant information via AR supports the setup personnel in various ways. Firstly the contents for the setup procedure, unlike in classical manuals, can be enhanced with various media such as photos, videos, and audio recordings. Additionally, information can be filtered and displayed to meet particular needs and situations. When using AR glasses/goggles, the operating personnel also have both hands free for practical work. Besides the setup process, the startup phase is also assisted by coSAM for the selection of suitable process parameters. The preparation of the AR contents using coSAM is intuitive and requires no special IT knowledge, so making usage easy and improving the acceptance of the system by personnel..


Efficiency increase using the coSAM assistance system

Setup processes are becoming ever more complex due to the greater diversity of products, smaller batch sizes, and more versatile machinery. Hence optimization of these processes is becoming ever more relevant from an economic perspective. The availability of customized information is vital for the setup personnel. AR devices (tablets, data glasses/goggles) are facilitating this as well as enhancing operating freedom via, for example, the elimination of operating manuals. Furthermore, after a successful setup process, the process parameters used for the startup phase are automatically optimized via an algorithm. This means a shorter startup time, quicker production of quality-compliant products, and fewer product rejects. These aspects significantly increase the efficiency of production plants.


Putting research into practice – application in industry

The development of the self-optimizing assistance system for setup processes is being carried out by the Fraunhofer IVV Dresden, development partners (Actimage GmbH and InQu Informatics GmbH), and also application partners from industry in order to take into account wishes, ideas, and concerns at an early stage in the development of the system..

This work is enabling the Fraunhofer IVV Dresden to further expand its expertise in plant operator assistance systems. Initially a functional model of the system will be built and tested on a laboratory scale at the Fraunhofer IVV Dresden. The system will then be installed and evaluated under practical conditions at two associated project partners..

Are you interested in the self-optimizing assistance system for AR-assisted machine setup or would you like further information about the coSAM project?  Then please get in touch with us!


Further Project Information


Project duration: November 2019 to October 2022

Project partner:


Deutsches Zentrum für Luft- und Raumfahrt e. V.

German Aerospace Center (DLR)