VASS PLC programming services
Are you carrying out a project for the Volkswagen Group and looking for experts in the VASS standard? We relieve integrators and machine manufacturers of the Volkswagen Group’s rigorous requirements. We specialize in programming PLCs strictly according to the VASS guidelines. We deliver 100% compliant, clean code, guaranteeing peace of mind at every stage of the project and a hassle-free passage through strict technical inspections.
What does VASS-standard PLC programming include?
We create PLC software fully tailored to the rigorous guidelines of the Volkswagen Group. We build the program based on the required architecture, implementing unified function blocks, standardized diagnostics, and algorithms for the safe and efficient control of technological installations.
Why entrust us with VASS PLC programming?
We fully understand the realities of production. We deliver code compliant with the VASS structure, combining the rigorous requirements of the automotive industry with many years of experience from factory floors. We have turned this practice into a repeatable implementation model. Thanks to the standards we have developed, we eliminate unforeseen risks and reduce the entire project to a clear, smoothly executed process.
Predictable implementation
A precise action plan is a guarantee of a smooth launch. We eliminate the risk of delays and unplanned downtime by following proven procedures at every stage of implementation.
Partnership approach
Implementing software that complies with rigorous standards requires discipline. To ensure timeliness and trouble-free acceptance, we base our collaboration on three pillars.
Experienced team
We eliminate the risk associated with handing tasks over to random subcontractors. Implementation is carried out by our in-house specialists, which translates into full commitment, quality control and clear responsibility for the result.
Do you need support with VASS-standard PLC programming?
Selected technologies we use for VASS PLC programming
The VASS architecture imposes strict hardware and software constraints. Working with approved components and dedicated libraries, we deliver systems uncompromisingly tailored to the corporation’s rigorous requirements.
PLC software
Implementation of dedicated software in the TIA Portal environment for Siemens S7-1500 controllers and safe migrations from older systems (S7-300/400) to the new architecture.
HMI visualization and diagnostics
Designing and generating operator interfaces in the Siemens WinCC environment, using SiVArc and the official VASS templates and libraries, ensuring full compliance with the structure of navigation, alarms and diagnostics.
Industrial robotics
Integration of robot controllers (with particular emphasis on KUKA VKRC as well as Fanuc and ABB) with the implementation of VASS communication interfaces, the PROFIsafe protocol and dedicated safety packages (SafeOperation, DCS, SafeMove).
Integration of devices and technological processes
Implementation of process equipment, including welding systems Harms+Wende and ARO, bonding and dispensing systems SCA and Dürr, tightening controllers Bosch Rexroth and Atlas Copco, servo presses and material joining systems TOX, Kistler and Böllhoff, as well as vision and marking systems.
Configuration of drives and inverters
Commissioning of drive systems based on SEW‑Eurodrive solutions (MOVIDRIVE, MOVIGEAR, MOVIFIT) and Siemens SINAMICS (G120, S120), connected via integrated PROFINET and PROFIsafe communication.
Identification and vision systems
Integration of RFID systems (Siemens SIMATIC RF, Balluff) and cameras and vision systems (Cognex, Keyence, ISRA Vision) using standardized functional blocks.
Machine safety
Implementation of reliable systems based on the PROFIsafe bus, including the integration of zone interlocking locks (Euchner MGB), safety light curtains, and laser scanners.
Parent interfaces
Implementation of official VASS interfaces ensuring reliable communication of PLC stations with higher-level production management systems and systems for tracking the flow of materials and parts.
Are you looking for a trusted partner to deliver advanced automation built to automotive standards?
Consult your VASS project.
For which production areas do we offer VASS-standard PLC programming?
We provide engineering support for key technological areas in Volkswagen Group factories. We ensure a precise sequence of movements, rigorous quality gating, and full traceability of the parameters of every component.
Car body construction and welding shop
Programming of automated cells and robotic lines responsible for shaping and joining the vehicle structure. We implement control logic for resistance welding, structural bonding, as well as riveting and clinching of sheet metal. We ensure precise synchronization of robot operations, positioning of components within strict geometric tolerances, and cooperation with welding technology.
Main assembly
Creating control code for automatic and semi-automatic assembly stations. We program complex tightening sequences with full torque and angle control, control press-fitting and crimping systems for components, and create logic for manual workstations. We provide on-screen step-by-step operator guidance, control of correct part pickup, and mechanisms to prevent errors.
Paint shop and sealing
Software for robotic applications for applying sealing, sound-deadening and protective compounds. We provide continuous control of pressure, quantity and geometry of the applied material. We program safe control of dedicated conveyors, lifts and technological transfer systems adapted to operate in the specific environmental conditions of the paint shop.
E-mobility and the battery area
Implementation of software projects for assembly lines of battery packs and electric drives. We program processes for the automatic application of thermally conductive compounds, precise placement of modules and integration of test stations. We implement the logic for automatic enclosure leak tests and electrical measurements with an immediate process lockout in case irregularities are detected.
Assembly of engines and drive systems
Programming of automated assembly lines for powertrain units, gearboxes, and chassis components. Developing logic for precision component assembly stations, automated test stations, and dosing stations for oils and service fluids. We ensure rigorous control of fit/tolerance parameters and full tracking of the parameters of each assembled unit.
Transport, quality control and IT
Comprehensive control of process transport lines, roller and chain conveyors, lifts, and integration with autonomous self-propelled vehicles. We program automatic visual inspection systems, readouts of identification carriers, and quality gating. We guarantee reliable transmission of complete process data packages to plant-level supervisory systems, ensuring full traceability of every product.
How do we work with our clients?
No two implementations are identical. Whether you need on-site developer support or are looking for a partner who will assume full responsibility for the entire implementation — we will flexibly join your team. We offer two clear models of collaboration and division of responsibility.
Model 1: Programming support
We increase the processing capacity of your engineering department. We relieve the team in PLC programming and we assist with the commissioning of machines at the customer’s site. We provide system integrators and machine manufacturers with the support of experienced engineers who will help safely complete the project on time.
Model 2: Turnkey implementation
We offer a comprehensive turnkey model designed for companies that expect implementation services from A to Z. We carry out the full cycle of work – from preparing the software architecture and interfaces, through the integration of robots and process equipment, to testing, cycle time optimization and start-up support.
Industry leaders trusted us
Star Assembly LLC
Sebeș, Romania
Audi
Győr, Hungary
BMW
Steyr, Austria
Stellantis
Mirafiori, Italy
BMW
Dingolfing, Germany
Daimler
Brühl, Germany
NIDEC
Niepołomice, Poland
Skoda
Mlada Boleslav, Czech Republic
Liebherr
Bischofshofen, Austria
Festo
Budapest, Hungary
Daimler
Untertürkheim, Germany
Dana
Amal, Sweden
Scania
Södertälje, Sweden
Volkswagen
Polkowice, Poland
Volkswagen
Salzgitter, Germany
Daimler
Redford, USA
Daimler
Kassel, Germany
Getrag
Cologne, Germany
Getrag
Bordeaux, France
Daimler
Jawor, Poland
Bosch
Charleston, USA
Magna
Tychy, Poland
ZF
Toluca, Mexico
JLR
Wolverhampton, Great Britain
Examples of projects that we have carried out for the Volkswagen Group
Implementation of new types on the cylinder head assembly line and the block lines – Škoda Auto
Assembly line ACT EVO Haube – Volkswagen Salzgitter
Ask about engineering support for projects based on the VASS standard.
FAQ – Frequently Asked Questions
Which production zones do you program to the VASS standard?
We program the full range of factory departments – from body shop and welding shop, through paint shops, main assembly, e‑mobility and engine assembly areas, all the way to transport systems and quality control. We support both automated robot cells and semi-automatic and manual stations with operator guidance.
How does a project carried out according to the VASS standard proceed?
After analyzing the specifications and auditing the requirements, a dedicated technical leader establishes with you the details, schedule, and division of responsibilities. Once the arrangements are approved, our engineers prepare the software. We operate according to proven procedures and checklists, and finally the same specialists carry out on-site commissioning, optimize cycle time, and assist during technical acceptance.
What does the cost of VASS-standard PLC programming depend on, and what does the pricing look like?
The cost depends on the number and type of workstations, the complexity of technological processes, the selected cooperation model, and the scope of integration with higher-level plant systems. We prepare a precise estimate based on an audit of the technical specification, the functional documentation, and the list of process equipment.
Do you provide on-site support during commissioning and acceptance?
Yes, the nature of Volkswagen Group’s rigorous requirements absolutely demands it. Our engineers take part in signal tests, technological commissioning, integration of the station into the main line, and official technical acceptances, providing support up to the moment of a stable start of production.
Do you provide training in software operation for operators and engineers?
Yes, we provide training for operators and maintenance personnel. We teach the operation of HMI interfaces, the use of diagnostics and quick fault localization on the panels, enabling technical staff to operate the line independently and smoothly after implementation.
After final acceptance, can we make changes to the software ourselves?
Yes, after completion of the implementation and final acceptance, we hand over a complete, open PLC and HMI project compliant with the VASS structure. Your maintenance team receives full access to the program structure, enabling independent diagnostics, routine servicing, and later expansion of the line.
Contact us – we will respond within 24h!
Do you have questions about VASS-standard PLC programming? 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 you are interested in. Then we will conduct an internal analysis of your inquiry to prepare the best possible solution.
Within a maximum of 5 business days we will get back to you with information about the next steps.
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