HCU module assembly line – Punch Powertrain & Stellantis
Comprehensive commissioning and optimization of an advanced assembly line for HCU modules at two international locations.
Client
Punch Powertrain (Belgium), Stellantis (France)
Scope of cooperation
PLC programming, commissioning and optimization of the line
Implementation period
2023 (Punch Powertrain), 2025 (Stellantis)
Project languages
English
About the project
Collaboration with Punch Powertrain and Stellantis resulted in the execution of a project for an advanced assembly line of HCU modules, which are critical for modern powertrains. The project included the commissioning of the first line in Belgium in 2023 and, subsequently, in 2025, the replication and commissioning of its duplicate at a French factory. Our goal was to ensure trouble-free operation and high production efficiency by integrating diverse technologies into a coherent system.
Scope of work
Our team of specialists in industrial automation provided comprehensive support during the line commissioning process. Two years after the first commissioning, we successfully participated in the implementation and start-up of a second, identical installation. The main scope of our activities included PLC programming, the integration of subsystems and the commissioning of both stages, which allowed the achievement of the expected production parameters.
Key elements of the scope
1) Programming and configuration of PLC
Implementation of control algorithms for four controllers Siemens Simatic S7-1500, including sequential logic for manual and automatic stations.
2) Integration with MES/ERP systems
Establishing a stable and efficient communication with the supervisory Aveva system, ensuring the exchange of production and status data in real time.
3) Implementation of advanced assembly processes
Integration of stations with pressing processes (TOX Pressotechnik), precision screwing (Desoutter), manipulation of small elements using pneumatic cylinders with force/position control.
4) Implementation of vision systems
Configuration and calibration of Omron vision systems for quality control and assembly verification.
5) Communication with a robotized cell
Ensuring smooth and safe communication between the PLC controller and the robotic cell responsible for the loading and unloading of elements.
Project challenges
The project was characterized by a high degree of complexity, stemming from the need to integrate many diverse technologies and the necessity of ensuring identical functionality and performance in two geographically distant locations. It was also crucial to meet the rigorous quality and efficiency standards of the automotive industry.
Main challenges
Technologies and solutions used in the project
| PLC control | Siemens Simatic S7-1500 |
| Programming platform | TIA Portal |
| Superordinate systems | Aveva (ERP/MES) |
| Presses | TOX Pressotechnik |
| Assembly tools | Desoutter (screwdrivers) |
| Vision systems | Omron Vision |
| Actuating elements | Pneumatic actuators with position/force control |
| Integration | Communication with a robotized cell |
Effects and benefits for the client
The most important results
• Start-up of two fully functional HCU module assembly lines.
• Minimizing assembly errors by implementing precise vision systems and force/position control.
• Seamless exchange of production data with the ERP/MES system (Aveva).
• Achieving the required production takt time, increasing overall efficiency.
• Ensuring the repeatability of assembly processes in two factories.
Added value for the Punch Powertrain factory (Belgium), Stellantis (France)
Thanks to a professional approach to programming and commissioning, the client gained not only two efficient production lines but also a cohesive system with high repeatability. This enabled the standardization of processes across different locations, providing easier management, reduced operating costs, and a solid foundation for potential further expansion or scaling of production.
Why do clients choose us for projects?
Our experience in programming Siemens controllers in TIA Portal, in combination with knowledge of the specifics of the automotive industry and the ability to integrate diverse technologies, was crucial to the success of this project. The ability to effectively manage complex implementations on an international scale and reliable support during start-ups at two factories confirmed our value as a trusted partner in industrial automation.
Summary
The HCU module assembly line project for Punch Powertrain and Stellantis was a comprehensive challenge that allowed us to demonstrate the full scope of our competencies in PLC programming and commissioning of advanced systems. The successful implementation at two locations, combined with the integration of multiple technologies and supervisory systems, confirms our ability to execute even the most demanding projects in industrial automation.
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