Implementation of new types on the cylinder head assembly line and the block lines – Škoda Auto
Comprehensive implementation of new production variants and optimization of the assembly processes of cylinder heads and engine blocks in Škoda Auto plants.
Client
Škoda Auto
Scope of cooperation
PLC programming, vision systems, drives, measurement devices
Implementation period
2024–2025
Project languages
Polish, English, Czech
About the project
The project at the Škoda Auto plants in Mlada Boleslav focused on a challenge critical to the automotive industry – the implementation of new types of parts on existing cylinder head and engine block assembly lines. The goal was to enable series production of new variants, significantly accelerate the production cycle time, integrate with the higher-level IMIS system and provide comprehensive training for operators and maintenance departments. In 2024 the team concentrated on adapting existing stations to the new type, adjusting the software PLC to mechanical and electrical changes. The changes included advanced press-fitting, bonding and leak-testing processes, while maintaining full support for the existing types. The year 2025 brought the implementation of another type, further software modifications and cycle-time optimization, again with the key requirement of maintaining backward compatibility.
Scope of work
Our role in this project involved the comprehensive implementation of software changes. PLC and the integration of vision systems, drives and measurement devices. We provided adaptation of the software code for new product variants, carried out controller migrations, and also optimized production cycle times. Our team, consisting of 3 PLC programmers in 2024 and 2 in 2025, was responsible for testing, commissioning and ongoing production support after deployments.
Key elements of the scope
1) Implementation of new product types
Adaptation of existing production stations on the assembly lines for cylinder heads and engine blocks to accommodate new part variants in 2024 and 2025.
2) Modernization of PLC software
Adjustment Siemens S7 PLC software for mechanical and electrical changes, including migration to newer PLC controllers and Sinumerik panels at selected stations.
3) Optimization of cycle time
Carrying out software modifications and providing support for mechanical changes to shorten the production cycle time to the required level, streamlining the process.
4) Integration of advanced processes
Software integration with press-fitting processes (Bayer KWP, Kistler maXYmos), bonding (DreiBond) and leak testing (Bayer DLP).
5) Production support and training
Providing production support after the completion of deployments, adaptation of the program in connection with the replacement of dosing controllers, and comprehensive training for operators and maintenance departments.
Project challenges
The project was characterized by a high degree of complexity, stemming from the need to introduce innovations on operating production lines of strategic importance to the client. A key challenge was ensuring full backward compatibility, which meant maintaining functionality for previously produced types while simultaneously implementing new solutions. Mechanical interventions often affected the operating range of older variants, requiring precise software modifications. Additionally, shortening cycle time to ambitious levels, integrating with advanced measurement systems, and ensuring the stability of adhesive bonding and sealing processes under time pressure were elements that required expertise and experience.
Main challenges
Technologies and solutions used in the project
| PLC controllers | Siemens S7-300 |
| Drives | Sinamics S120, SIMODRIVE |
| Vision systems | Keyence, Cognex cameras |
| Measuring/actuating devices | Trumpf laser engraver, Bayer DLP leak tester, Measurement of the pressing process Bayer KWP, Kistler maXYmos |
| Software | Simatic Manager, TIA Portal, STARTER, SimoCom U, WinCC Flexible, HMI PRO, Cognex Dataman, Keyence Software |
Effects and benefits for the client
Most important results
• Serial production of new types of cylinder heads and engine blocks has been successfully launched.
• The production cycle time has been significantly shortened, meeting the set operational objectives.
Full integration with the higher-level production management system IMIS has been provided.
• Continuity of production and full support of the existing product types has been maintained.
• Operators and maintenance departments have been comprehensively trained on the new solutions.
• Complex technological processes, such as press-fitting, gluing and leak tests, have been optimized and stabilized.
Added value for the Škoda Auto factory
Thanks to our actions the client gained significant flexibility in production, the ability to quickly introduce new models without the need to build new production lines. Optimization of cycle time resulted in increased throughput and a reduction in operating costs. The long-term added value also includes increased reliability and stability of processes, as well as the readiness of the infrastructure for further modifications thanks to the use of modern solutions and migration to newer controllers. The project contributed to strengthening Škoda Auto’s position as an innovative manufacturer in the automotive industry.
Why do clients choose us for projects?
Our experience in the automotive industry, backed by numerous projects for leading manufacturers, has enabled us to effectively meet the rigorous requirements of Škoda Auto. We possess expert knowledge in the field of controller programming in TIA Portal and Simatic Manager, which was key to the effective modernization and integration of systems. The ability to work with a variety of vision systems (Keyence, Cognex), drives (Sinamics, SIMODRIVE) and advanced measuring devices, combined with the ability to manage complex projects requiring backward compatibility, distinguishes our company as a trusted partner. Our dedicated team of programmers provided rapid adaptation, professional commissioning and necessary on-site production support.
Summary
The project at Škoda Auto is an example of a successful implementation of a complex rollout of new product types on existing assembly lines, which encompassed comprehensive PLC programming, integration of vision and measurement systems, and cycle time optimization. Thanks to our actions, the client achieved a significant acceleration of production processes, ensured backward compatibility, and attained readiness for series production of new variants, strengthening its position in the automotive market.
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