AUTOMOTIVE
Engine Assembly Line Automation
Complete integration of Power & Free and loop conveyor systems for a 47-station engine assembly line. PLC programming, safety system validation, and production launch support—delivered on schedule with zero quality escapes.
Tier 1 Supplier — Stellantis | Michigan, USA
THE CHALLENGE
Engine Assembly Line Challenges
Tight Timeline
The customer had a fixed PPAP date with Stellantis that could not move. Any delay would mean penalties and potential loss of the contract.
Multi-Vendor Coordination
Equipment was coming from six different OEMs, each with their own PLC code, I/O standards, and communication protocols. Someone had to make it all work together.
Zero Tolerance for Errors
Engine assembly is safety-critical. Every torque specification, every fastener sequence, every interlock had to be validated. Quality escapes were not an option.
Production Pressure
The existing plant was already running production on adjacent lines. Integration work had to happen without disrupting current operations.
OUR SOLUTION
Our Engine Assembly Automation Solution
PLC Programming & Integration
We developed the master PLC logic to coordinate all 47 stations, integrating code from multiple OEMs into a unified Allen-Bradley ControlLogix architecture.
- Station sequencing and interlock logic
- Conveyor zone control and accumulation
- Error handling and recovery routines
- Production tracking and data collection
Power & Free Conveyor Integration
The overhead Power & Free system required precise coordination with floor-level operations.
- Carrier tracking and routing logic
- Accumulation zone management
- Automatic vs. manual mode transitions
- Fault recovery sequences
Safety System Validation
Working with GuardLogix safety PLCs, we validated all safety interlocks.
- E-stop circuits and zone isolation
- Light curtain integration
- Two-hand control stations
- Safety-rated conveyor stops
Launch Support
Our engineers were on-site during the production launch.
- Real-time troubleshooting during ramp-up
- Operator and maintenance training
- Documentation and IPF mapping
- 30-day post-launch support
SPECIFICATIONS
Engine Assembly Technical Details
THE RESULTS
Engine Assembly Line Results
The line launched on the scheduled PPAP date—16 weeks from project kickoff. No delays, no penalties.
First engines off the line met all Stellantis quality specifications. Zero escapes during initial production runs.
Line achieved 99.2% first-pass yield within the first month—exceeding the 98% target.
Unplanned downtime averaged less than 15 minutes per shift during the first 90 days.
Engine Assembly Automation Services
Need Engine Assembly Automation?
Whether you're launching a new line or upgrading existing equipment, our automation engineers can help. Let's talk about your project.
Response within 24 hours · Free consultation
