JAGUAR LAND ROVER
UK
Automation of a measurement cell for electric motor production
WHY?
The story:
Production keeps moving, but the process needs to improve
In an automotive factory, integrating a new operation into an existing production line comes with a significant challenge: production must continue.
At Jaguar Land Rover, the bitYes team was involved in a project to introduce a new inspection operation into an electric motor production line.
The objective was to inspect the rotor circumference by integrating a measurement cell and an industrial robot into the existing process.
The challenge? Implementing and testing the new operation during ongoing production, without stopping the line.
WHAT?
The challenge:
A new inspection operation within an existing process
- Integrating a measurement cell to inspect the rotor circumference.
- Integrating a KUKA robot into the existing process.
- Adapting the Siemens PLC program to accommodate the new operation.
- Testing the cell during ongoing production.
- Adapting the implementation to changes in the manufactured components.
- Improving cycle time and optimizing cell operations.
HOW?
The solution:
Siemens PLC, KUKA robot, and carefully coordinated integration
The bitYes team integrated a measurement cell and a KUKA robot into the existing automation system, controlled by a Siemens PLC.
The new operation enables rotor circumference inspection as part of the electric motor manufacturing process.
Technologies and integration:
- Siemens PLC.
- KUKA industrial robot.
- Measurement cell for rotor circumference inspection.
Implementation stages and technical challenges:
- Integrating the new cell into the existing automation logic.
- Testing functionality under real production conditions.
- Implementing changes requested by the client throughout the project.
- Adapting operations to modifications in the manufactured components.
- Optimizing cycle time and cell performance.
In a project like this, programming is only one part of the solution. Equally important are coordination with the existing production process, thorough testing, and the ability to adapt the implementation without disrupting production.
WHAT WAS ACHIEVED?
The result:
Integrated dimensional inspection. Uninterrupted production.
The project resulted in the integration of a measurement cell into the existing production process, in accordance with Jaguar Land Rover’s standards.
Seamless integration: The new inspection operation was implemented without stopping production.
Adaptability: The solution was adjusted to accommodate changes in manufactured components and evolving client requirements.
Operational efficiency: Cycle time and cell performance were key optimization priorities throughout the implementation.
The project demonstrates that an existing production line can be enhanced with new operations without shutting down the manufacturing process during implementation.
CLIENT THOUGHTS?
Trust is built during implementation
“Integrating a new inspection operation into an active production line was a significant challenge for us. The bitYes team demonstrated flexibility and the ability to respond to changes throughout the implementation, successfully integrating the measurement cell into the existing process without interrupting production.”
– Jagurar Land Rover Representative
BACKSTAGE
Safety first. Even at pedestrian crossings.
International projects bring technical challenges, but also a few unexpected cultural lessons.
At the Jaguar Land Rover factory, one of our bitYes colleagues discovered that even crossing the road could become a conversation starter.
Accustomed to looking left first before crossing, he caught the attention of local technicians, who jokingly asked where he was from.
The reason? In the UK, traffic drives on the left, so the first instinct should be to look right.
A simple but memorable lesson: in automation, adaptability matters. And sometimes, it starts before you even reach the PLC.
