Implementation of generation 3 on the engine line – Stellantis Tychy
Comprehensive modernization and expansion of the internal combustion engine assembly line for Stellantis in Tychy, enabling the production of the latest generation of engines.
Client
Stellantis Tychy
Scope of cooperation
PLC programming, commissioning, start-up of new stations
Implementation period
2023
Project languages
Polish, English
About the project
In 2023 our experts carried out a key implementation of generation 3 on the existing assembly line of internal combustion engines at the Stellantis plant in Tychy, which had until then been configured for production of generation 2. The aim of the project was to ensure a smooth transition to the new generation of the product while maintaining continuity and operational efficiency. Our specialists in PLC programming played an important role in the realization of this technically advanced undertaking.
Scope of work
Our role in the project included comprehensive support in PLC programming and system commissioning. Two of our experienced PLC programmers were responsible for numerous modifications to existing automatic and manual stations. Additionally, as part of the project, we carried out commissioning of two completely new automatic stations, which constituted a key element in adapting the line for production of generation 3.
Key elements of the scope
1) Modifications of existing stations
Carrying out numerous software and configuration modifications on existing automatic and manual stations, with the aim of adapting them to the production requirements of generation 3.
2) Start-up of the valve assembly station
Implementation and commissioning of a new automatic valve assembly station in the head, located on the head assembly line. The station’s control is based on Siemens controllers.
3) Commissioning of the camshaft assembly station
Integration and commissioning of a new automatic camshaft assembly station in the module, located on the main assembly line of internal combustion engines. This station used Allen-Bradley controllers and advanced oil dispensing systems (Dobotech) and camshaft cap tightening systems (Bosch).
Project challenges
The main challenges of the project involved the complex integration of a new-generation product with the existing line infrastructure in a production environment with high demands for precision and cycle times. It was necessary to maintain the continuity of the line’s operation while simultaneously implementing significant technical and software changes.
Main challenges
Technologies and solutions used in the project
| PLC controllers | Siemens (TIA Portal), Allen-Bradley |
| Mounting systems | Dobotech oil supply system |
| Mounting systems | Bosch (system for screwing on bridges) |
Effects and benefits for the client
The most important results
• Successful implementation of production of third-generation internal combustion engines on the existing line.
• Increasing the flexibility and adaptability of the production line to new market requirements.
• Effective commissioning of two new, advanced automated stations that streamline the assembly process.
• Ensuring stable and reliable operation of the modified line at the Stellantis plant.
Value added for the Stellantis factory – engine production plant in Tychy
Thanks to our competencies in designing industrial automation systems, Stellantis has gained a modern and flexible production line capable of manufacturing the latest generation of engines, which translates into increased market competitiveness, reduced long-term operating costs, and shortened time to market. The improved assembly processes have also contributed to an improvement in the quality of the final product.
Why do clients choose us for projects?
Our extensive experience in the automotive industry, combined with advanced skills in PLC programming for Siemens and Allen‑Bradley systems, allowed us to effectively manage the complexity of the project. The ability to collaborate effectively in an international team, rapid adaptation to new challenges, and a focus on achieving concrete, measurable results set our company apart in the execution of this key undertaking.
Summary
The Generation 3 implementation project on the internal combustion engine assembly line for Stellantis in Tychy was a technical and logistical challenge that our specialists successfully executed. Thanks to a comprehensive approach to PLC programming, the integration of new stations and the modification of existing systems, the production line was effectively adapted to the latest standards, providing Stellantis in Tychy with the capability to produce innovative powertrains.
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