Today, a variety of assembly technology, including electric screwdrivers, torque wrenches, bar code scanners and pick-to-light systems, are “smart” devices. They are equipped with sensors and network connectivity, allowing them to instantly receive instructions and return feedback about their performance in real time.

For example, assemblers can use connected torque wrenches to apply the just the right amount of torque to a bolted joint. These tools can be programmed with minimum and maximum torque values to ensure that every fastener is tightened correctly. When integrated with VKS, these tools can stop the workflow if something goes wrong. The software will log every successful or failed attempt, ensuring quality control.

Similarly, connected devices such as bar code scanners, digital calipers and smart scales can send data in real time directly to VKS Smart Forms. Bar code scanners quickly capture important information like serial numbers or part IDs, which helps with tracking. Digital calipers measure parts accurately for quality checks, and smart scales ensure that packages or assemblies weigh what they’re supposed to. These devices reduce the need for manual data entry, lower the chances of mistakes, and simplify record-keeping in regulated settings.

Pick-to-light systems help workers find the right parts during assembly. When connected to VKS via IO Connect, these systems light up the correct bin or part based on the current step in a digital instruction guide. After the worker picks a part, a sensor confirms the action and moves VKS to the next step automatically. This close integration helps reduce mistakes, ensures accuracy, and makes workflows smoother by visually guiding assemblers through the process.

A variety of functions in the software make this happen. For example, with VKS ToolConnect IoT, tools are automatically configured for each task. For instance, when an operator opens a work instruction for engine assembly, the connected torque wrench instantly receives the right torque settings for each of the bolts in the workflow. This automation cuts down on setup time, minimizes mistakes, and speeds up production.

Similarly, with Torque Tool Validation, smart tools check if the correct torque has been applied and alert the operator if it hasn’t. A smart nutrunner integrated with VKS can stop the instructions and notify the assembler if a fastener has not been tightened correctly.

Manufacturers also have the option to allow or prevent employees from skipping important steps when using integrated smart tools, specifically when it comes to tool annotation. This gives teams better control over how integrated smart tools are used with their work instructions.

When the anti-skip function is activated, workers must use a smart tool to complete the ToolConnect step before they can continue with the next part of the work instruction. When it’s deactivated, workers can skip the ToolConnect steps and continue moving through the instructions without using a smart tool. However, when they do this, the action is recorded in a report, and supervisors receive a notification.

In highly regulated industries, being able to track every action is crucial. Smart tools log every important tool detail, while VKS tracks operator IDs, date, time, serial numbers and other data. 

With VKS, production data and tool performance can be updated instantly with MES and ERP systems. This smooth connection gives everyone in the company real-time visibility into the assembly process, helps automate decision-making, and keeps all operations aligned from start to finish.

New product lines and changes to the ERP can trigger VKS to auto-create, clone, update, and publish instructions with the correct product and revision numbers. For instance, when a new product or revision number is entered in an ERP system, VKS can instantly generate a fully linked work instruction that includes accurate routing information. 

Another new feature, IO Connect, allows engineers to directly link digital work instructions with physical machines, PLCs, sensors, cobots and other shop floor devices. With IO Connect, engineers can trigger machine actions directly from a step in a digital work instruction. They can receive input from sensors, confirming completion of a task. They can lock and unlock tools or workflow steps based on sensor and equipment data. And, they can monitor pick-to-light systems, andon lights, vision systems, and other error-proofing technologies.

For more information on digital work instructions, click https://vksapp.com or visit the company’s booth at The Manufacturing & Automation eXchange (MAX), which will be held March 25-26, 2026, at the Music City Center in Nashville, TN. 

MAX was created in direct response to the shifts shaping manufacturing today: smart factories, integrated systems, workforce challenges, and the need for collaboration across disciplines. MAX merges the strengths of five manufacturing brands—ASSEMBLY, Quality, Adhesives & Sealants Industry, ISHN, and Packaging Strategies—to create one collaborative, unified event that reflects how modern manufacturers think, work, and solve.