Not attending any of these events but still interested in learning more?
Reach out to us and we'll get back to you in no time.
When Virtual Reality Meets Artificial Intelligence: How Freudenberg Medical is Transforming Training and Factory Layout Planning
Freudenberg Medical is redefining manufacturing by combining Virtual Reality (VR) and Artificial Intelligence (AI) to enhance training, streamline production, and drive efficiency across global sites. With new facilities underway in Germany and Costa Rica, this innovative approach is giving customers greater transparency and collaboration while cutting costs, reducing waste, and setting new standards for the future of production layouts.
Freudenberg Medical first implemented Virtual Reality (VR) training in 2022 at its Carrick-on-Shannon site in Ireland to train employees in catheter manufacturing. VR-based training enhances new operator onboarding tailored to the individuals’ pace, and cuts costs by lowering training scrap and line downtimes. “We can achieve so much more without increasing costs,” said Séamus Maguire, Vice President, GROWTTH and Lean Systems. The success led the company to build its own VR expertise and expand the training to other global sites.
Creating Immersive, Accurate Training Environments
To take this initiative to the next level, Freudenberg hired Darian Zeis, a Computer Science Engineer, in Jeffersonville, Indiana, to develop an immersive VR training environment that mirrors the exact conditions of the production floor. “Operators need to learn very specific steps like mixing adhesives or applying them on a mandrel accurately. A lack of precision could lead to quality issues,” explained Zeis.
He worked directly on the production floor to understand common mistakes, refining the VR scenarios to address real-world challenges. Standardized training across different locations captures critical ‘tribal knowledge’ from experienced operators. An online training database documents operator training progress and ensures consistency across global locations, whether in the US, Ireland, or Costa Rica.
Developing AI Solutions for Smarter Factory Layouts
Zeis recently advanced to Freudenberg Technology Innovation at the Freudenberg Group headquarters in Weinheim, Germany. He works on a strategic program called ‘Virtual Factory Solutions’, aimed at revolutionizing production layout planning through AI. He is now developing AI algorithms to optimize production floor layouts by working closely with lean manufacturing and production engineers.
Catheter manufacturing, in particular, requires many manual steps that must be precisely coordinated to adhere to established takt times, which is crucial for efficient production. “The goal is to improve the flow of production by determining the optimal placement of all items,” he noted. “This includes everything from conveyor belts and tables to machinery and even where operators should stand or sit to minimize walking distance.”
"With VR and AI, we can start planning the production layout of new sites, like the Freudenberg Medical sites currently being constructed in Costa Rica and Germany even before the buildings are completed. We have the flexibility to modify the building setup before construction is finalized, which is a massive advantage in optimizing space and workflow."
Séamus Maguire, Vice President, GROWTTH & Lean Systems
Planning Factories of the Future Before They're Built
This proactive approach not only enhances efficiency but also ensures that the factory layout is documented and streamlined, avoiding the need for costly adjustments post-construction. In addition, customers can be involved early-on. “VR helps to overcome the common fear of change among customers by involving them in the production planning process, making it a collaborative and transparent experience,” reiterated Maguire. “That is especially beneficial when transferring production lines to more cost-efficient countries such as Costa Rica.”
Setting New Standards in Training, Production Efficiency, and Customer Collaboration
Zeis’ background in computer engineering and science has been instrumental in tackling the complex challenges associated with VR and AI technology. “My brain likes to solve problems,” he said, “from creating efficient models to addressing biological constraints to prevent motion sickness of the operators.” Through its innovative use of VR and AI, Freudenberg Medical is setting a new standard in training, production efficiency, and customer collaboration, all while keeping an eye on sustainability and cost-effectiveness.
