Smart Assembly: Integrating Pick-to-Light Guidance with Labview Vision Inspection for Time-Efficient Manufacturing

In the context of Industry 4.0, the need for intelligent operator-assistive technologies has driven interest in hybrid systems that improve efficiency in manual-centric assembly workflows. Traditional manual methods often lack structured task sequencing, resulting in variable performance and extended completion times. This paper presents the development of a Pick-to-Light (PTL) assembly guidance system, integrated with LabVIEW Vision Builder for Automated Inspection (VBAI), aimed at improving assembly time performance and ensuring real-time validation. The system features IR (infrared) sensor-activated trays and dynamic projection overlays to guide users through part selection and placement, with all signal logic managed via a MODBUS-based graphical interface using TCP/IP (Transmission Control Protocol/Internet Protocol) communication. A structured experimental study was conducted to compare the system's effectiveness against traditional manual assembly methods by assembling a computer motherboard. Results show that a significant reduction in average assembly time from 3.03 minutes (manual) to 2.16 minutes (PTL-guided prototype), representing a 28.7% improvement in time efficiency. This indicates an overall improvement of approximately 47 seconds per participant when using the PTL-guided prototype. This gain is attributed to reduced decision-making time, improved task visibility, and real-time visual feedback. The findings demonstrate that combining interactive pick signaling with spatial visual guidance offers a practical and scalable solution for improving time efficiency in manual assembly environments, particularly for small-to-medium-scale manufacturers transitioning toward smart, semi-automated manufacturing environments.