Future-Proofing Automated Body Handling Operations:
The Challenge
A leading luxury automotive manufacturer required modifications to its existing automated body storage and handling facility to support the introduction of new vehicle variants whilst maintaining compatibility with existing production models.
The challenge was to create a universal handling solution capable of accommodating multiple vehicle body types and stillage configurations without disrupting ongoing production operations. Existing load stations, transfer systems, and body lifting equipment required detailed investigation, modification, and recommissioning to ensure compatibility with future vehicle programmes.
The project demanded a solution that would maintain operational flexibility, minimise downtime and support future production growth whilst utilising as much of the existing infrastructure as possible.
Our Solution
ASKI Automation was engaged to provide a complete turnkey engineering solution, including:
- Detailed site investigation and engineering assessment.
- Mechanical modifications to existing automated load stations.
- Recommissioning of body locking and positioning systems.
- Validation of new vehicle body handling arrangements.
- Modification of transfer and centring mechanisms to support multiple vehicle variants.
- PLC software modifications and controls integration.
- Electrical design and commissioning support.
- 3D simulation and process validation.
- Project management, installation and commissioning services.
Our engineering team reviewed the complete body handling process, identifying critical interaction points and implementing modifications that enabled the facility to process multiple vehicle variants through a common handling platform.
The solution incorporated upgrades to body positioning systems, transfer mechanisms, sensor arrangements and automation controls to deliver a flexible and scalable operation.
Key Deliverables
- Modification of existing automated load stations.
- Integration of multiple vehicle body variants.
- Recommissioning of legacy handling equipment.
- Mechanical and controls engineering upgrades.
- PLC software development and optimisation.
- Site validation and performance testing.
- Simulation modelling and throughput analysis.
- Full project management and installation support.
Results
The upgraded facility successfully increased operational flexibility by enabling multiple vehicle variants to be processed through a common handling system.
Key benefits included:
- Reduced capital expenditure through reuse of existing infrastructure.
- Improved flexibility for future vehicle programmes.
- Enhanced automation and process reliability.
- Reduced manual intervention.
- Increased operational efficiency through optimised handling sequences.
- Future-proofed production capability for upcoming model introductions.
ASKI Automation Capability
This project demonstrates ASKI Automation’s ability to deliver complex brownfield automation projects within live manufacturing environments. By combining mechanical engineering, controls expertise, simulation, project management, and installation services, we provided a complete turnkey solution that enhanced production capability whilst minimising operational disruption.
From concept through to commissioning, ASKI Automation delivered a flexible, reliable, and scalable solution designed to support the client’s future manufacturing requirements.