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Hit The Brakes: Is automotive manufacturing shifting into the automated lane?

Published: 08/07/2022

Hit The Brakes: Is Automotive Manufacturing Shifting Into the Automated Lane?

As a pioneer of the automotive industry, Ransom Olds invented the world's first automotive assembly line in 1901. This shift meant production output increased by 500% per annum when manufacturing his popular Curved Dash model, producing a total of twenty vehicles per day. Otherwise known as the Model 6, with streamlined production, this was the first vehicle to be mass produced and it was on his foundations where Henry Ford began building.

As the 20th Century progressed, Ford used the concept of moving platforms within a conveyor belt system. The chassis of the vehicle was moved between platforms using a tow rope where the factory employees would assemble each component. As the 1950s and 60s rolled around, automated robotics were becoming progressively involved in the automotive industry. General Motors were trailblazers in robotics throughout the sixties, installing an arm to assist with vehicle assembly, performing repeated actions accurately. 


Automation is nothing new for the automotive industry. In fact, it has been keeping the wheels of manufacturing turning for decades, impacting each stage of the production process. The automotive industry is undergoing an automation revolution, welcoming cobots, 3D printing and the Industrial Internet of Things to create endless possibilities.


So, where is automation prevalent throughout the automotive manufacturing process?

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The Rise of Cobots

Automated technologies are incorporated to carry out many tasks from welding and vehicle assembly to producing body components and even creating the engine itself. Cobots have become an integral part of the automotive production process with robots and humans working side by side, each essential cogs in the manufacturing machine. Upon their inception, there was significant worry that robots would replace their counterparts. Traditionally, robots were introduced to perform repetitive elements of the manufacturing process which would be potentially hazardous for a human employee. However, with the advancement of technology, the two have joined together to collaborate, hence the term cobots. A good example would be welding. If you have ever handled a welding machine and accidentally received a nasty flash, the next few days would have been hellish as you itched your eyes into oblivion. Well, using automated robots takes this risk and throws it into the ether. 

BMW utilises cobots to reduce risk to their human workforce as door components are manufactured accurately. These cobots are so safe and reliable that a safety fence is not even required.

“Robots that assist production workers by assuming labor-intensive tasks will characterize the factory of the future. Their benefits are strength and mechanical accuracy – and they perfectly complement humans’ flexibility, intelligence and sensitivity.”

Harald Krüger, member of the Management Board of BMW AG, responsible for production.

BMW are not alone in embracing automation during their production process. Multinational manufacturer Ford Motor Company also sees the resounding benefits of these technologies. Selling over sixteen million of their Fiesta models since the 1970s, cobots have been introduced to ensure consistent bodywork  and polished finishing touches. Described as a choreographed sequence of events, the cobots are trusted to operate near high end audio equipment and most importantly, they tackle the most laborious tasks while the human workforce focuses elsewhere. Sanding  a vehicle's bodywork can take up to two hours per panel depending on the car type, however these cobots sand the entire vehicle in just over thirty seconds. 

“The cobots can feel when more force needs to be applied, just like we can, and they can more easily get to hard-to-reach places, like the centre of the roof.” 

Dennis Kuhn, Senior Manufacturing Engineer, Paint Shop, Ford of Europe.

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Fusing Additive Manufacturing with Automation

3D printing has certainly made its mark on the automotive industry and is most known as additive manufacturing, capable of printing with a wide variety of materials. The machine creates the component in layers and minimises the need for welding which takes a longer period of time to merge the desired materials together. 3D printers Wohlers conducted market research which revealed that just over 16% of all 3D printing carried out in 2015 was attributed to the automotive industry. Six years later, it is safe to say that this number is inflating. Rapid prototyping at lower costs becomes a possibility and customisation transforms into an endless realm. This form of robotic manufacturing allows for the condensation of the supply chain with OEMs utilising 3D printing as opposed to waiting for third parties to import finished automobile components. Peter Bartels of Volkswagen views 3D printing as “additional capabilities that strengthen 3D printing operations and allow further optimization of the design process.”

With electric vehicles becoming increasingly popular (accounting for 7.2% of car sales in 2021), manufacturers are well aware of the impending ban of petrol and diesel cars on the horizon. From 2030 and as this ban comes into action, new vehicles must be electric. 3D printing has already demonstrated its aptitude for this, creating Olli the electric minibus in 2016 where 80% of its parts were printed. Manufacturer Local Motors also created an electric two seated vehicle consisting of 75% printed components. With these significant developments, 3D printing and automation go hand in hand to further optimise the automotive manufacturing process, plugging into the future and making the switch to the electric lane. 

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IIoT Based Decision Making

The Industrial Internet of Things opens doors to incredible connectivity and optimisation. When machinery is connected throughout the automotive manufacturing process, data is shared between the two through the use of sensors and analytical software, providing greater insight into each stage of manufacturing. Every piece of information from task completion time to the management of inventory is covered. Using these sensors, the supervisor is able to create an accurate, all encompassing view of the production line. Having this tool under their belt means inefficiencies and anomalies can be identified and rectified  as a predictive and preventative maintenance method before they become a far larger problem. For instance, automotive components can be tracked as they progress through the manufacturing process. If a component is recalled for lacking quality, it is then possible to pinpoint the location in which things took a downward turn. Whether it is overheating or something more serious such as an electrical fault, the deployed sensors have the ability to identify the error. 


Industry 4.0 has brought ever evolving technologies onto the factory floor, allowing automobile manufacturers to optimise production management with these IIoT solutions. Decisions can be made based on such varied data, saving production time and therefore supplying the demand much faster. For example, sensors may show that one stage of the assembly process is taking longer than expected and so the decision is made to replace the automated machinery operating in that zone. Tracking the performance, this operational decision would have a huge knock on effect rippling from the factory itself to the end user. 

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No matter your automation requirements, Northern Industrial has you covered.

From replacement sensors and HMIs to electrical repairs and obsolete spare parts, we are committed to optimising your operations. Industrial automation is part of our DNA. If you are on the hunt for a complete automation solution for your automotive manufacturing process, we are ready and waiting to provide the integrated support you deserve in the fight against unplanned downtime.

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