ACT EVO Hood assembly line – Volkswagen Salzgitter
Comprehensive implementation of an engine cylinder head assembly line project for a key player in the automotive industry, including automatic, semi-automatic and manual stations.
Client
Volkswagen Salzgitter
Scope of cooperation
PLC programming, robot programming, commissioning (commissioning)
Implementation period
2019
Project languages
German, English, Polish
About the project
In 2019, in cooperation with our partner, we carried out an innovative ACT EVO Haube assembly line project for the Volkswagen plant in Salzgitter, Germany. The aim of the project was to create an advanced line for assembling VW engine cylinder heads, integrating various technologies and processes to optimize production and ensure the highest quality. The project was key to modernizing assembly processes in one of the leading manufacturing plants in the automotive industry, aligning with our competencies in the field of design of industrial automation systems.
Scope of work
Our team, composed of six experienced programmers and roboticists, was responsible for the comprehensive software and commissioning of fully automated, semi-automated, and manual stations. The scope of work included the integration of advanced control systems, robot programming and the implementation of quality control systems to ensure the smoothness and precision of assembly processes. Our services in the field of PLC programming were the foundation of the success of this project.
Key elements of scope
1) Programming of robotic assembly workstations
Implementation of the control logic for two large robotic cells equipped with KUKA robots, responsible for assembling the camshaft, and a smaller cell with a Universal Robots collaborative robot for precision fastening.
2) Integration of advanced production processes
Software and configuration of specialized processes in automatic and semi-automatic stations, including controlled tightening (CLECO mPro), precision press-fitting and pressing (Kistler systems), advanced visual inspections (Keyence) and laser marking (TRUMP TruMark).
3) Optimization of manual workstations and quality control
Design and implementation of solutions supporting operators at manual workstations, such as the assembly of modules and coils using poka-yoke component racks and Cognex post-assembly vision inspection systems to eliminate errors.
Project challenges
The ACT EVO Haube assembly line project for Volkswagen was characterized by a high level of technical complexity and precision, resulting from the requirements of the automotive industry. Key challenges included the integration of diverse technologies from multiple suppliers and the need to ensure flawless synchronization of all elements of the production line.
Main challenges
Technologies and solutions used in the project
| PLC control | Siemens S7-1500 (TIA Portal) |
| Robotics | KUKA, Universal Robots |
| Vision systems | Keyence, Cognex |
| Screwing systems | CLECO mPro |
| Ironing systems | Kistler |
| Marking | TRUMP TruMark |
| Component management | Poka-yoke |
Effects and benefits for the client
Most important results
• Successful integration of advanced automation and robotics systems within a single production line.
• Significant increase in the precision and repeatability of engine head assembly.
• Shortening the takt time for assembly operations by optimizing automated processes.
• Improvement of ergonomics and efficiency of manual workstations.
• Achieving full compliance with Volkswagen’s rigorous quality and safety standards.
Added value for the Volkswagen Salzgitter factory
The implementation of the project contributed to increasing the competitiveness of the Volkswagen factory in Salzgitter by modernizing key assembly processes. The client gained a reliable, flexible and highly precise production line capable of adapting to future requirements, which translates into lower operating costs, reduced errors and a guarantee of the highest quality of the final products. The optimized processes also led to more efficient use of resources and a faster return on investment.
Why do clients choose us for projects?
Our experience in carrying out complex projects for the automotive industry, including broad competencies in programming of KUKA robots and collaborative robots were crucial to the success of this project. The team of six highly skilled programmers and roboticists provided a comprehensive approach and flexibility in solving complex technical challenges. We prioritize precision, timeliness, and a complete understanding of the client’s specific needs, as evidenced by our successful collaboration with such a prestigious brand as Volkswagen.
Summary
The ACT EVO Haube assembly line project for Volkswagen Salzgitter served as confirmation of our capabilities in the comprehensive automation and robotization of production processes. Thanks to the commitment of a specialized team and the application of the latest technologies, we delivered a solution that not only met but exceeded the client’s expectations, contributing to raising the standards of quality and efficiency in the production of VW engine cylinder heads.
Contact us – we will reply within 24h!
Do you have questions about production automation? Fill out the contact form, and our team will contact you within 24 hours – by phone or email.
During the conversation or correspondence, we will jointly determine the scope of the work and services you are interested in. Then we will carry out an internal analysis of your inquiry to prepare the best possible solution.
Within a maximum of 5 business days we will get back to you with information about the next steps.
Take a step towards modern automation – fill out the form now!
