Automating Automotive Manufacturing

The use of robotics in the automotive factory is not recent. In fiction, it traces back to 1921, in the play Rossum’s Universal Robots and in reality, to 1961 when the first application of robots was seen in the automotive industry. For decades now, robots have been helping factories streamline processes, enhance productivity, and eliminate human error and risks. As a result, the automotive industry continues to reach new milestones as today’s robots evolve into nuanced structures that use more effective technologies. 

In this blog, we will explore the various processes that can be automated, particularly during the manufacturing of two-wheelers. The current manufacturing process in the industry implements two methods: line assembly and Just-in-time manufacturing. 

Every step in automotive manufacturing, ranging from welding, assembly, and mainly material handling can be enhanced with robots. Factories deploy robots for routine, monotonous tasks as they are prone to human error and danger. Such automation across heterogeneous processes has been possible because of flexible and adaptable solutions. 

If we take a close look at 2-wheeler manufacturing, the complete process is categorised based on sub-assemblies. Further, the final vehicle assembly line is fed with these sub-assemblies and other components, in the required order, to create the final product. Here are more details about the process. The sub-assemblies are brought onto the main assembly line using a material handling system. At the same time, the other components are stacked on the side as they’re to be installed at various stations. 

The major assemblies in the 2-wheeler include (a) Frame Assembly, (b) Engine Assembly, (c) Front Wheel Assembly, (d) Rear Wheel Assembly, (e) Seat Assembly.

Botsync, Augmenting Existing Processes

Recently, we have identified yet another industry and process for its automation solutions – two-wheeler manufacturing. 

Automation in this industry, as mentioned above, has been around for over 60 years now. However, the shift from automated guided vehicles (AGVs) to autonomous mobile robots (#AMRs) is new. With a growing need for flexibility and adaptability, AMRs are the next much-needed technology for the auto industry to improve productivity and efficiency. 

Recently, our team has recognised processes in the two-wheeler manufacturing that can be automated and improved by our automation solution for automotive manufacturers. In a non-automated 2-wheeler factory, material handling is done by towing/pushing the sub-assemblies and components such as wheels, frames, engines, tools and more, to the main line. At this stage, the assembled frame and engine are prepped for the main line. It involves towing/pushing across all stages like forging, machining, welding, and assembling various components. This translates to manual action taking place, approximately, across 10 stages!

An automated material handling process, on the other hand, replaces towing/pushing at each stage. Most factories today use a combination of manual and robotic solutions.  For the manufacturing of 2-wheelers though, we have been able to identify an end-to-end automation solution for material handling. 

With our MAG AMRs, we are automating multiple processes such as engine movements for our customers. This series can automate the movement of pallets/trolleys/carts/custom loads of up to 1000 kg (lifting) or 1500 kg (tugging). They’ve been built keeping in mind the heterogeneous nature of materials in factories. Additionally, such results have been possible not just because of  AMR capabilities, but also due to the experience our front-end, syncOS, offers. 

To take your 2-wheeler factories to the next level with industrial automation, get in touch with us here.

Published by botsyncblog

Botsync is a robotics startup that helps companies automate their material movement operations at existing plants or warehouses. Our automation platform allows users to configure, deploy and change settings of AMRs without any technical capability. Our MAG AMR series can automate movement of pallets/trolleys/carts/custom loads of up to 1000 kg (lifting) or 1500 kg (tugging) without any changes to existing infrastructure.

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