Case Study · Automotive
Automotive & Tier-1
Line-side delivery of seat assemblies and weld fixtures, synchronized to takt time — with a robotic spray cell for cosmetic parts.
30%
Floor-space saving
99.2%
Delivery on-time
2 yr
Payback period
24/7
Line-side uptime
The Challenge
Takt-time pressure and line-side chaos
A global Tier-1 seat and weld-fixture supplier was losing delivery-on-time performance to manual material flow:
- ▸Seat assemblies and heavy weld fixtures moved by hand across a 4,800 m² hall, causing line-side congestion.
- ▸Delivery-on-time below 92% under takt-time pressure and skilled-labour shortage.
- ▸Cosmetic weld fixtures required consistent, repeatable spray finishing that manual booths could not guarantee.
The Solution
Synchronized line-side automation
We deployed a turnkey cell combining mobile robots, a robotic spray arm and AI vision:
- ▸Fleet of AGVs performing line-side delivery synchronized to takt time with +/-5mm SLAM docking.
- ▸6-axis robotic spray cell with consistent film thickness for cosmetic weld fixtures.
- ▸AI vision docking and fleet orchestration running 24/7 with auto-charging.
How it was delivered
Site audit
Two-week takt-time and material-flow analysis across a 4,800 m² assembly hall.
Cell design
AGV line-side delivery paired with a 6-axis robotic spray cell for cosmetic weld fixtures.
Go-live
Commissioned in 14 weeks with vision-based +/-5mm docking and synchronized takt release.
Scale-out
Fleet expanded to 9 AGVs with centralized fleet orchestration.
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