Car window motor assembly line – Brose
Commissioning and optimization of an advanced production line for car window control motors, ensuring the stability and efficiency of the assembly process.
Client
Brose Prievidza plant (Slovakia)
Scope of cooperation
PLC, robotics, HMI, transport systems
Implementation period
2020
Project languages
English, Slovak
About the project
The project carried out at the Brose Prievidza plant (Slovakia) included the comprehensive start-up and optimization of a production line intended for the assembly of power window motors. The main objective was to achieve maximum process stability and a significant improvement in key production indicators, including defect reduction and takt time optimization. Our actions contributed to an increase in efficiency robotization of production in the plant.
Scope of work
Our activities focused on the comprehensive commissioning and optimization of the key stations of the assembly line. They included both work in the area of PLC programming, as well as the integration of diverse systems, in order to ensure the smooth and efficient operation of the entire installation in accordance with the stringent standards of the automotive industry.
Key elements of the scope
1) Start-up of assembly stations
Activation and precise configuration of automatic stations responsible for the assembly of seals, bushings, rotors and stators of automotive motors.
2 Optimization of the production cycle
Analysis and optimization of the takt times of individual stations and of the entire production line, aimed at reducing the cycle time and improving the NOK rate.
3) Standardization of PLC software
Implementation of consistent programming standards in the TIA Portal v15.1 environment for all PLCs on the line, which facilitated diagnostics and future modifications.
4) Integration of transport systems
Connection and synchronization of the operation of the advanced Bosch Rexroth ActiveMover magnetic transport system and Weber component feeders with the main line control.
Project challenges
A project in the automotive industry is always associated with high demands for precision, reliability and meeting strict deadlines. It was crucial to ensure flawless assembly of components while maintaining micron-level tolerances, to optimize cycle times at each station, and to enable seamless integration of diverse systems from different manufacturers.
Main challenges
Technologies and solutions used in the project
| Control | Siemens SIMATIC IPC, TIA Portal v15.1 |
| Visualization | Siemens HMI |
| Robotics | Epson robots |
| Providing components | Weber feeders (screws, bushings, gaskets) |
| Transport | Bosch Rexroth ActiveMover magnetic transport system |
Effects and benefits for the client
Most important results
• Optimization of the production cycle: Significant shortening of the line’s takt time, increasing its overall throughput.
• Reduction of the NOK rate: Minimizing the number of defective products through precise assembly and process stabilization.
• Standardization of PLC software: Implementation of uniform programming standards, which facilitated maintenance and service.
• Stable commissioning of assembly stations: Seamless transition of all stations into continuous and stable operation.
• Increased stability and quality: Overall improvement in the reliability of the line and the quality of the motors produced.
Added value for the Brose factory
Thanks to the implemented solutions, Brose achieved a significant improvement in key production indicators, which directly translated into lower operational costs, increased efficiency and improved overall product quality. Software standardization provided easier maintenance, diagnostics and future scalability of the system, minimizing the risk of downtime and facilitating further development.
Why do clients choose us for projects?
Our extensive experience in implementing complex projects for the demanding Automotive industry, as well as a deep knowledge of advanced technologies, such as PLC controller programming and robot programming, made it possible to effectively resolve all challenges. The team of experienced programmers and engineers provided not only the commissioning but also the optimization of the line, going beyond the Client’s standard expectations.
Summary
The project at the Brose Prievidza plant is an example of a successful implementation, where precision, optimization and standardization of key assembly processes translated into tangible business benefits for the Client. It confirms our ability to deliver advanced solutions in industrial automation that meet the highest industry standards and support the production goals of our partners.
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