Cylinder Head Assembly for V8 Engine – Jaguar Land Rover (NC11)
The project involved the commissioning and integration of an assembly line for the production of V8 engine cylinder heads (NC11 – V8 Assembly Line).
Client
Jaguar Land Rover – Wolverhampton Engine Manufacturing Centre (United Kingdom)
Scope of work
PLC Programming • Robotics • Vision Systems • Integration with Supervisory Control Systems
Project duration
2023–2024
Project languages
Polish, English, German
About the project
The project involved the commissioning and integration of an assembly line for the production of V8 engine cylinder heads (NC11 – V8 Assembly Line). The line consisted of several stations: manual, semi-automatic, fully automatic, as well as a rework station.
The PLC software was developed in a modified version of the BMW TA standard provided by Insite, adapted to the strict requirements of Jaguar Land Rover. The entire assembly process was non-standard – the cylinder heads had to move in pairs (left + right), and the PLC together with the RFID system controlled the correct sequence and data consistency with JLR supervisory systems.
Scope of work
A team consisting of 7 specialists (6 PLC programmers, 1 robotics engineer) was responsible for the complete operation and integration of:
– PLC control systems,
– ABB robots,
– vision systems,
– transfer systems,
– integration with JLR supervisory systems,
– testing, optimization, and support for serial production.
The project also included training of the maintenance team and support during the initial months of mass production ramp-up.
Key scope elements
1) PLC Programming and Integration with JLR Supervisory Systems
– development and modification of PLC logic in the BMW TA standard,
– handling of transfer systems, buffers, and positioning systems,
– integration with systems: CIMPOS, CIMTRACK, Traceability, SCIEMETRIC, Overcheck,
– RFID communication and validation of cylinder head sequence (L/R),
– handling of EST screwdrivers and measurement systems.
2) Robotics – ABB
– programming of handling robots,
– programming of an ABB robot for automated quality inspection,
– integration with Vision Tools and camera systems,
– trajectory optimization and cycle-time optimization.
3) Vision Systems
– integration of Keyence cameras,
– integration of Cognex Dataman scanners,
– automated verification of assembly correctness,
– Vision Tools programming for final quality inspection.
4) Drives and Motion Control
– configuration of Sinamics S120 drives,
– synchronization of movements between stations and buffers,
– analysis of motion-control errors.
5) Transport System Commissioning
– configuration of the complete cylinder-head transport logic,
– validation of “L → R” flow across the entire line,
– prototype testing and sequence simulations.
Project challenges
The commissioning of the V8 assembly line was particularly demanding due to:
• operation on two parallel parts (left/right cylinder head),
• complex logistics of transfer systems and pairing of semi-finished components,
• integration with multiple JLR supervisory systems,
• the requirement to maintain full traceability at every process stage,
• working with a PLC standard that required extensive modifications.
Additionally, the line combined manual, semi-automatic, and fully automatic technologies – which required a unified approach to control logic and data validation.
Main challenges
Technologies and solutions used in the project
| PLC Controllers | Siemens S7-1500 |
| Robotics | ABB (handling + vision inspection) |
| Drives | Sinamics S120 |
| Vision Systems | Keyence cameras, Vision Tools systems |
| Scanners | Cognex Dataman |
| Assembly Tools | EST screwdrivers |
| Software | TIA Portal, ABB RobotStudio, Keyence Software, Cognex Dataman, Vision Tools |
| Supervisory Systems | CIMPOS, CIMTRACK, Traceability, SCIEMETRIC, Overcheck |
Project outcomes and client benefits
Thanks to the team’s work and full integration of all technologies:
Key results
stable serial production of V8 cylinder heads was achieved,
full traceability was implemented in compliance with JLR requirements,
complete line compatibility with CIMPOS and CIMTRACK systems was ensured,
robot and drive sequences were optimized,
critical quality tests were automated using robots and vision systems.
Added value for the JLR factory:
educed production ramp-up time,
high process stability from the first months of line operation,
consistent integration of multiple technologies: PLC, robotics, vision, peripherals,
complete documentation and training for the maintenance team,
possibility for future expansion and scaling of the V8 assembly line.
Why Clients choose us for commissioning projects?
– many years of experience in large-scale automotive projects,
– expertise in Siemens PLC programming and working with OEM standards,
– combined competencies: PLC + robotics + vision + system integration,
– efficient international collaboration (PL–DE–UK),
– support from initial commissioning through to full serial production,
– capability to deliver additional services: EPLAN design and control cabinet prefabrication.
Project Summary
The NC11 project for Jaguar Land Rover is an example of a comprehensive integration of an advanced assembly line combining automation and robotics, vision systems, motion control, and traceability solutions. Thanks to the team’s experience and a unified engineering approach, stable serial production and full compliance with JLR requirements were successfully achieved.
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