CASE STUDY / TIER 1 AUTOMOTIVE / JULY 2026
Automating the
unautomated.
A manual assembly process became a flexible robotic system. The challenge went beyond rate: the equipment needed to handle part variation and remain useful beyond the current vehicle programs.
INSIDE THE SYSTEM
SELECT A STAGE TO EXPLORETwelve robots.
One connected process.
PROCESS OVERVIEW · ILLUSTRATIVE SEQUENCE, NOT A CELL LAYOUT
PART PRESENTATION + CUSTOM EOAT
A repeatable pick starts before the robot moves.
Feeders present small components. A revised gripper stop, conveyor timing, and magnetic positioning help stabilize the delicate conductivity-ring pickup.
The challenge
Assemble seven components across left- and right-hand variants for two models. Fit the process into a constrained footprint, with robots that could be redeployed for future programs.
The engineering
Mechanical design and controls teams addressed tolerance stack-up and delicate component handling together. One PLC system coordinates robots, presses, riveting, inspection, and packaging.
The outcome
The system exceeds its contracted cycle requirement. One person loads raw components; the remaining assembly sequence is automated. The published case study details the team’s commissioning work on the customer’s floor.
THE FULL TECHNICAL STORY
Read the original five-page Ethos case study for the robot selection, tooling decisions, controls integration, and commissioning detail behind the result.