Robots in Car Manufacturing: What the Future Holds for Auto Makers
Automotive plants sprawl. Workers strain under heavy loads. Parts are misplaced. Mild errors stall production. The cost of clinging to outdated methods is too high to pay. Especially today.
Avoiding ongoing and preventable recalls and rework costs has a solution. We’re talking about a force that empowers you to be a manufacturing hero:
Of course, we mean the use of robots in car manufacturing!
This article dives deep into how robotics transforms the automotive industry, exploring the switch from traditional assembly lines to advanced autonomous vehicle production.
Tag along and gain insight to plan for your plant’s next big move.
The Role of Automation in the Automotive Industry
The automotive industry has always been a battleground of innovation, a race to deliver quality vehicles faster and cheaper. Today, automation champions robotics, the key to victory in a heavily competitive field.
Gas Powered Vehicles
For decades, automation has been the backbone of traditional car manufacturing. Yet, many plants still grapple with inefficiencies. Think of the paint shop, where human error leads to costly rework, or the assembly line, where repetitive tasks cause worker fatigue and injuries.
Modern robotics is kicking past issues to the curve by prompting these benefits:
● Consistent quality and precision in welding, painting, and assembly.
● Increased production speed and reduced cycle times.
● Improved safety and reduced risk of worker injuries.
Electric Vehicles
The rise of EVs is a paradigm shift. These vehicles demand a new level of precision and efficiency. From battery assembly to complex electronic systems, automation is a necessity.
What is robotic automation bringing to the table?
● Precise handling of delicate battery components.
● Efficient assembly of complex electronic systems.
● Scalable production to meet the growing demand for EVs.
How Automotive Manufacturers Are Integrating AMRs and Robotics
Automakers are no longer just dreaming of automation. They’re implementing it. That’s right, automotive plant automation is happening now.
Across the factory floor, cobots in automotive assembly are working alongside human operators, increasing productivity and precision.
Autonomous Mobile Robots (AMRs) are navigating complex logistics, ensuring parts are delivered just in time.
The old days of workers pushing heavy dollies across the plant are fading fast. The new era backed by AMRs, cobots, and other robotic systems is taking off, enabling:
➔ Seamless material handling.
➔ Faster assembly.
➔ And precise quality control.
With less reliance on manual labor and fewer errors, auto manufacturers can optimize workflows, improve safety, and boost overall productivity.
Automotive Plant Automation: Trends Shaping the Future
The automotive industry is in constant motion, and automation is evolving at an even faster pace. Let’s look at the trends that are already making noise into the future.
Advanced AMR Integration and Customization
Today’s AMRs are highly intelligent and adaptable. They move parts. They optimize workflows. And they deliver delicate components into tight spaces.
AMRs can be customized according to operational needs. For EV production, where battery handling and precise component delivery are essential, they’ve become essential.
By dynamically adjusting their routes based on real-time production data, any AMR fleet can attenuate bottlenecks and boost efficiency.
AMRs are crucial for a fully automated, flexible factory.
Flexible and Modular Automation
The ability to adapt to changing production demands is crucial. Modular robotic systems allow manufacturers to reconfigure their assembly lines with ease, responding to market shifts with agility.
This trend is a must-have for the fast-changing EV market and companies looking for autonomous vehicle manufacturing.
Nissan’s Intelligent Tochigi Plant in Japan is a prime example. After switching to flexible and modular robotics to handle various tasks, they saw a meaningful reduction in energy consumption and 25% CO2 emissions in the painting process.
Cobots
Cobots are ideal for dynamic manufacturing environments. They are designed to work alongside human workers, enhancing productivity and safety.
For instance, Ford uses cobots to grease camshafts, fill engines with oil, and perform quality inspections.
Other applications are car seat assembly and attaching door handles and windshield wipers.
Successful Automation and Robotics Applications in the Automotive Industry
Let’s look at some real-world examples of how automation is driving success.
Tesla’s Gigafactory
Tesla’s Gigafactory is a testament to the power of automation. From battery production to vehicle assembly, robots play a crucial role in achieving high production volumes.
BMW’s Smart Factory
BMW’s smart factory uses AMRs and cobots to streamline operations and enhance flexibility. The approach led to improved production efficiency and reduced downtime, demonstrating the benefits of a fully automated manufacturing environment.
Toyota’s Automated Production Line
Toyota implemented advanced robotics in their production line, resulting in an increase in production efficiency and a reduction in defects. Their success showcases the potential of automation to transform manufacturing processes.
Shiloh Industries’ Improved Efficiency with Robotic Welding
Shiloh Industries is a global supplier of lightweight, noise, vibration, and harshness (NVH) solutions for the automotive industry. They implemented robotic welding systems in their production lines for critical components and achieved:
● Increased weld consistency: Robotic welding ensured precise and repeatable welds, reducing defects and improving product quality.
● Reduced cycle times: Automation sped up the welding process, leading to faster production and increased throughput.
● Improved worker safety: Robots handled the physically demanding and potentially hazardous welding tasks, reducing the risk of worker injuries.
ROI Breakdown
Investing in robotics is a strategic move that delivers significant returns.
ROI Timeline
The ROI timeline for robotics automation investments can vary based on the scale and complexity of the implementation.
Fig. 1. Typical ROI timeline for robotics implementation in car manufacturing.
Generally, manufacturers can expect to see a return within 1-2 years.
Ongoing benefits include:
➔ Reduced labor costs.
➔ Increased productivity.
➔ Improved quality.
Investment Budget
The investment budget varies according to company size and scale. However, we can offer you this traditional investment range and potential annual savings:
Fig. 2. Referential investment budget and potential annual savings from robotics deployment in the automotive industry.
Conclusion
Is robotics the ultimate performance enhancer for the automotive industry?
It’s as close as it’ll ever be.
AMRs, cobots, or other advanced robotics automation are a must to stay ahead in car manufacturing practices for gas/diesel or electrically powered vehicles.
Besides cutting costs and building a future where efficiency, quality, and safety go hand in hand, robotics is about making you a manufacturing hero in front of your peers, competitors, and customers.
But you don’t have to go it alone.
Verdusco Automation is your partner in this journey.
We offer:
➔ AMRs and advanced robotics solutions, from assessment to implementation.
We help you:
➔ Ensure a smooth transition to a fully automated future.
Contact Verdusco Automation today:
📩 Get in touch now: https://www.verduscoautomation.com/contact.
