BOSCH
SERBIA
One Assembly Line. Multiple Products. The Same Flexibility.
Automation of an assembly line for the automotive industry
WHY?
The story:
When the product changes, the production line must keep up
In the automotive industry, production flexibility is essential. An assembly line does not always have to be dedicated to a single product. Sometimes, the same infrastructure must support the manufacturing of multiple models, each with its own specific requirements.
This was the challenge of the Bosch Serbia project, where the bitYes team worked on automating an assembly line for different models of automotive wiper arms.
The objective was to develop an automation application that would allow the process to adapt to the product being manufactured, without compromising operator safety.
WHAT?
The challenge:
Multiple models. One adaptable assembly process.
The client needed to automate an assembly line capable of producing different models of automotive wiper arms.
Each product variant required specific assembly steps, and the automation system had to accommodate these differences.
The main requirements included:
- Adapting assembly sequences to the product model being manufactured.
- Programming a Beckhoff PLC according to the manufacturing process.
- Integrating safety modules to protect operators.
- Implementing an HMI interface for interaction with the production line.
The challenge was to find the right balance between process flexibility, production efficiency, and operator safety.
HOW?
The solution:
Flexible automation built around the production process
The bitYes team programmed the Beckhoff PLC according to the assembly process and the specific steps required for each product type.
Both the PLC program and the assembly line were designed to adapt to the model being manufactured.
Technologies and integration:
- Beckhoff PLC for assembly process control.
- Safety modules integrated into the automation application.
- HMI interface for system operation and interaction.
Key features:
- Managing assembly sequences according to the product being manufactured.
- Adapting line operations to different automotive wiper arm models.
- Integrating safety functions into the automation logic.
- Enabling operators to interact with the system through the HMI.
Particular attention was given to integrating safety functions into the application, ensuring that production requirements and operator protection were addressed together from the programming stage.
WHAT WAS ACHIEVED?
The result:
Production flexibility. Operational safety.
The project resulted in an automated assembly line capable of adapting to different automotive wiper arm models.
Flexibility: The PLC program and assembly line can be adapted according to the product being manufactured.
Efficiency: The system’s adaptability supports efficient organization of the assembly process.
Safety: Integrated safety modules help ensure that equipment operates in accordance with the safety requirements defined for the application.
Operation: The HMI allows operators to interact with the production line.
The project demonstrates that an effective automation solution must meet both current production requirements and the need to adapt to different products.
CLIENT THOUGHTS?
A solution tailored to production requirements
“We needed an automation solution that would allow the assembly line to adapt to different product models while maintaining operator safety. The bitYes team understood our process requirements and developed a flexible PLC application tailored to our production needs”
– Bosch Representative
BACKSTAGE
In automation, sometimes you need a little GURAJ! 😄
In international projects, some of the most memorable moments happen in the most unexpected places.
At Bosch Serbia, the bitYes team noticed an amusing detail: the exit doors in the production area displayed the sign “GURAJ / PUSH”.
In Serbian, “guraj” means “push”. But for our Romanian team, its similarity to the Romanian word “curaj”, meaning “courage”, was simply too good to ignore.
So we came to a conclusion that perfectly fits our profession:
Alongside rigorous programming, safe equipment, and well-designed processes, automation sometimes requires a little GURAJ too! 😄
Especially when working on new projects, in different factories, and facing challenges that are not always solved on the first attempt.
