Gearbox production line – Stellantis Italy
Comprehensive programming, commissioning and optimization of two advanced production lines for gearbox assembly for a global car manufacturer.
Client
Stellantis Italy (end customer)
Scope of cooperation
PLC programming, robot programming, commissioning, optimization, production support, MES system.
Implementation period
2023-2025
Project languages
English, Italian
About the project
This strategic project carried out at the Stellantis plant in Mirafiori, Italy, included the programming and commissioning of two advanced production lines for gearbox assembly. Our company, in cooperation with a leading integrator from France, was responsible for the adaptation and implementation of automation solutions, aiming to ensure maximum efficiency and reliability in the production of components for the automotive industry.
Scope of work
Our company was responsible for the comprehensive servicing of 40 production stations of various types – automated, robotic, semi-automatic and manual – together with transport systems. The task was PLC programming, adaptation of existing control programs to the specifics of the project, as well as carrying out the commissioning of the equipment and starting production. Additionally, we implemented an MES supervisory system, performing its configuration, testing and optimization. After successful commissioning, we provided over six months of production support, and then carried out process optimization to increase line efficiency by 10%.
Key elements of the scope
1) Programming and commissioning of 40 production stations
Adaptation and commissioning of control systems for various stations (automated, robotic, manual) and transport systems within two gearbox production lines.
2) Implementation and optimization of the MES system
Configuration, testing and optimization of the supervisory Manufacturing Execution System to ensure smooth management and monitoring of production processes.
3) Production support and takeover of additional stations
Ensuring the continuity of production on three shifts, 7 days a week, for over half a year, as well as the takeover and integration of an additional 24 stations into the existing system.
4) Comprehensive optimization of line performance
Redesign of the structure, electrical installation, automation and robotics systems at almost every station, resulting in a 10% increase in overall production line efficiency.
5) Integration of advanced technologies
Work with FANUC robotic systems, FESTO pneumatics, Atlas Copco and Weber assembly equipment, Kistler presses, Cognex vision systems, and specialized magnetization and HV testing stations.
Project challenges
This project was distinguished by its extraordinary complexity, stemming from the diversity of production processes and the vast scale of the installation. Each station carried out a unique stage of assembly or inspection, which required the team to possess broad knowledge across many disciplines. The greatest challenge, however, was the comprehensive reconstruction and the resumption of production within an extremely short, less-than-three-week timeframe, which placed high demands on the entire team for flexibility and readiness to react quickly.
Main challenges
Technologies and solutions used in the project
| PLC control | Siemens S7-1500 |
| Operator panels | Siemens Comfort HMI |
| Industrial robots | FANUC |
| Assembly tools | Atlas Copco |
| Feeding and assembly systems | Weber |
| Presses | Kistler |
| Dosing systems | SCA |
| Vision systems | Cognex |
| Measurement systems | Geometry control and selection of washers |
| Test stations | Automated HV tests |
| Specialist processes | Magnetization of rotors |
Effects and benefits for the client
Key results
• Thanks to comprehensive optimization, the client achieved a significant increase in gearbox production efficiency.
• Successful start-up of two complex production lines and ensuring their uninterrupted 24/7 operation for over six months.
• The implementation and configuration of the MES system streamlined production management and the monitoring of key indicators.
• The integration of advanced inspection and assembly technologies ensured the repeatability and accuracy of every stage of production.
• Professional technical support and rapid response to failures contributed to a reduction in downtime.
Added value for the Stellantis Italy factory (end customer)
The client gained not only an immediate 10% increase in gearbox production efficiency, but also long-term operational stability thanks to optimized processes and an effectively implemented MES system. The successful commissioning and maintenance of operations on such complex and critical production lines translates into reduced operating costs, minimized downtime, and increased predictability and scalability of future modifications. The availability of 24/7 support for an extended period after start-up ensured the security of the investment and a rapid response to any production challenges.
Why do clients choose us for projects?
Our company stood out in this project with comprehensive competencies in automation engineering, from adapting existing solutions and PLC programming, from programming FANUC robots to advanced optimization and long-term support. We have extensive experience in integrating diverse technologies as well as the flexibility and readiness to act quickly, which was crucial in the case of extremely short rebuild deadlines. Our multidisciplinary team, possessing expertise in robotics, pneumatics, hydraulics, and vision systems, effectively met the complexity of a large-scale project, delivering measurable results and added value for the end client.
Summary
The project at the Stellantis factory in Italy serves as confirmation of our comprehensive competencies in the automation and optimization of complex production lines. Thanks to the commitment and specialized knowledge of our team, we were able to effectively program, commission, and optimize two gearbox assembly lines, significantly increasing their efficiency and ensuring operational stability in a demanding industrial environment.
Contact us – we’ll respond within 24 hours!
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 a conversation or correspondence, we will jointly define the scope of the works and services that interest you. We will then conduct an internal analysis of your inquiry to prepare the best possible solution.
We will get back to you within a maximum of 5 business days with information about the next steps.
Take a step toward modern automation — fill out the form now!
