Commissioning of Rework Stations (REP) of the Flexible Line – Volkswagen Motor Polska
Comprehensive commissioning of four rework stations for the FLEX engine assembly line, providing flexibility in quality management.
Client
Volkswagen Motor Poland, Polkowice
Scope of cooperation
Commissioning and integration of automation systems
Implementation period
Third quarter 2025
Project languages
Polish, English
About the project
The project involved the offline preparation and commissioning of four repair stations Reparaturplatz – REP for the new Flexible line at the Volkswagen Motor Polska plant in Polkowice. The goal was to create flexible points where employees can efficiently perform collective assembly corrections of engines classified as NOK – Not OK in terms of quality. The FLEX line, characterized by a predominance of manual workstations, was designed with small-series production of various types of engines in mind, which required solutions providing high adaptability and advanced PLC programming.
Scope of work
Our role in the project included the comprehensive preparation and commissioning of four REP rework stations. The work was carried out both in an offline phase, which included preparing software and configurations, and directly at the client’s site, where the final commissioning and process optimization were performed. It was crucial to ensure full compliance with Volkswagen’s internal standards and the specifics of the Flexible line.
Key elements of the scope
1) Offline programming and programming of the Siemens S7-1500 controller
Development and testing of PLC control logic for each REP workstation using TIA Portal V19, in accordance with functional requirements and VW standards. As part of this stage, the following were carried out programming of Siemens S7-1500 controllers.
2) Implementation and configuration of HMI
Design and implementation of WinCC Advanced visualizations, providing operators with an intuitive interface for managing corrective processes and monitoring the status of workstations.
3) Integration of identification systems
Implementation and configuration of Balluff RFID readers and Cognex handheld scanners for precise tracking of NOK engines and components at every stage of the rework process.
4) Implementation and testing of I/O modules
Connection, configuration and carrying out input/output tests (I/O check) for Siemens and Balluf modules, ensuring reliable communication between the controller and the actuators.
5) Commissioning and on-site optimization
Final commissioning, functional and process tests directly at the customer’s plant, taking into account the specifics of the Flexible line and integration with the existing production systems of Volkswagen Motor Polska.
Project challenges
A key aspect of the project was to ensure full adaptation of the workstations to the flexible nature of the FLEX line, which handles small-batch production of multiple engine types. Despite having experience with twin workstations on the MDB EVO line, it was necessary to precisely tailor standards and processes to the specifics of the new production environment, which required detailed analysis and a flexible approach during programming and commissioning.
Main challenges
Technologies and solutions used in the project
| PLC control | Siemens S7-1512 |
| Programming environment | Siemens TIA Portal V19 |
| HMI Visualization | Siemens WinCC Advanced |
| Identification systems | Balluf RFID, Cognex handheld scanners |
| Input/Output Modules | Siemens I/O, Balluf I/O |
Effects and benefits for the client
The most important results
• Successful commissioning of four advanced repair stations (REP), increasing the throughput and efficiency of NOK engine servicing.
• Ensuring full flexibility of the Flexible line in quality management, which enables the production of multiple types of engines in small batches.
• Achieving full integration of automation and identification systems, guaranteeing precise process tracking and the minimization of operational errors.
• Delivery of a stable and reliable solution, ready for long-term operation in the demanding production environment of Volkswagen Motor Polska.
• Confirmation of the ability to adapt and expand existing know-how to new projects and client standards.
Added value for the Volkswagen Motor Polska factory
Thanks to our experience in implementing similar projects and our in-depth understanding of Volkswagen standards, the client gained not only ready-to-use workstations but also optimized processes that increase the flexibility of the entire production line. This results in the ability to quickly adapt to changing market requirements, more efficient management of engine quality, and a potential reduction in operating costs by shortening the time needed for adjustments and minimizing material waste.
Why do clients choose us for projects?
Our key advantages in this project stemmed from the team’s extensive experience in commissioning twin stations on the MDB EVO line. Possessing full know-how regarding the processes, standards and requirements of Volkswagen Motor Polska allowed for a significant shortening of the implementation time and the minimization of project risk. Additionally, our specialized skills in programming Siemens S7-1500 controllers A deep knowledge of the TIA Portal and WinCC Advanced environment was a guarantee of the high quality and reliability of the implemented solutions.
Summary
The project to commission four rework stations (REP) for the Flexible line at Volkswagen Motor Polska is an example of the effective use of acquired experience and specialist knowledge to deliver flexible and reliable automation solutions. Thanks to precise offline preparation and efficient on-site commissioning, we created systems supporting small-batch production of multiple engine types, while meeting rigorous industry standards and customer expectations. This project underscores our ability to execute complex tasks in a dynamic industrial environment.
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