Automating the Main Engine Assembly Line For a Leading Automotive Manufacturer in France
Overview
A leading automotive manufacturer in France partnered with ACL Digital to automate their Main Engine Assembly Line, covering requirements, development, testing, and on-site commissioning, with a focus on operational efficiency, error elimination, and system integr ation.
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Challenges
Manual Error Risk
High dependency on manual verification resulted in assembly defects and wrong part fitment
No Traceability
Absence of a digital engine history made component tracking and recall management difficult
Unplanned Downtime
Without centralized diagnostics, identifying faults was slow and entirely manual
Safety Risks from Heavy Payload Handling
Manual handling of large frames during hoist and gantry operations increased operator risk
Solution
- PLC and HMI Automation: Developed PLC control logic and HMI screens to automate assembly sequences and enable real-time monitoring
- Integrated Verification: Implemented barcode scanning and vision inspection to enable error-proofing at each s tage
- RFID-Based Tracking: Enabled digital capture and recording of each engine’s assembly history
- Virtual Commissioning: Delivered offline simulator-based testing to validate logic and third-party integrations prior to installation
Outcomes
- Reduced Assembly Errors: Automated stop-on-error logic ensures only verified engines proceed
- Complete Engine Genealogy: Full digital traceability of every assembled component, supporting regulatory compliance
- Faster Go-Live: Offline testing significantly reduced on-site commissioning time and startup issues
- Instant Fault Diagnosis: Operators can identify and resolve faults in real time through the HMI, reducing unplanned downtime
