Nowadays, there is an increasing trend towards advanced CNC machine tools having a high level of automation. Nevertheless, manually operated equipment is still playing an important role in many industrial workshops. Operators’ experience is still essential in the perspective of increasing productivity, enhancing product quality, reducing manufacturing costs related to tool wear, waste and maintenance. Thus, even manual operations that are apparently less important in terms of product added value may deserve attention and need to be improved according to the principles of the digital transformation era. This paper introduces a structured approach for design, development and implementation of an operator guidance system for a manual bandsaw machine, based on the digital shadow concept and additional feedback sensors. This provides an actual example of how the digital transformation of a small-scale equipment may improve the manufacturing performance and ergonomics as well.
