Automotive Powertrain Assembly Line Achieves 99.5% Uptime
32-station robotic assembly line for transmission components
Project Overview
Launching a new transmission program is a high-stakes endeavor. When a Tier 1 powertrain supplier won a major OEM contract, they needed an assembly line capable of producing 800+ units per shift with near-zero defects—all within an existing facility with limited floor space.
AMD Automation designed a high-density assembly line that packs 32 robot stations into a compact footprint while maintaining industry-leading uptime and quality.
Compact Cell Design
Space efficiency was critical. Our engineering team developed innovative cell layouts:
Dual-Robot Stations
Where traditional designs use one robot per operation, we configured cells with two robots working opposite sides of the pallet simultaneously, doubling productivity per square foot.
Overhead Services
Utilities, cables, and conveyors routed overhead keep the floor clear for maintenance access while maximizing usable space.
Integrated Buffers
Strategic buffer stations allow individual cells to cycle for maintenance without stopping the entire line.
Critical Fastening Operations
Transmission assembly requires precise torque control on dozens of fasteners:
- 48 critical fasteners per assembly
- DC electric tools with ±1% accuracy
- Angle monitoring verifies proper seating
- Automatic documentation for every fastener
Any out-of-spec torque immediately flags the unit and halts production at that station.
Launch Success
The line launched on the OEM's aggressive timeline:
- Week 1-2: Slow-speed validation
- Week 3-4: Ramp to 50% rate
- Week 5-6: Full production rate
- Week 7+: Sustained 99.5% uptime
The customer has since awarded two additional programs based on this line's success.
Customer Testimonial
"AMD Automation delivered a line that exceeded our expectations in every dimension—quality, throughput, uptime, and floor space. They're our go-to partner for complex assembly programs."
— Plant Manager, Tier 1 Powertrain Supplier
01The Challenge
A Tier 1 powertrain supplier needed to launch a new transmission program requiring high-volume assembly with zero quality escapes and minimal footprint in an existing facility.
- 800+ units per shift production requirement
- Sub-60-second takt time for complex assembly
- Floor space limited to existing building footprint
- Multiple torque-critical fastening operations
- 100% traceability for warranty and recall support
02Our Solution
AMD Automation designed a compact, high-density assembly line with 32 robot stations performing simultaneous operations, integrated error-proofing, and comprehensive data collection.
Multi-Robot Assembly Cells
Compact cells with multiple robots working simultaneously to maximize throughput while minimizing floor space.
Precision Fastening Systems
DC electric torque tools with angle monitoring ensure every critical fastener meets specification.
Integrated Leak Testing
In-line pressure decay testing verifies seal integrity before components proceed downstream.
Real-Time Quality Monitoring
Every operation tracked and verified with automatic production hold for out-of-spec conditions.
03The Results
The line launched on schedule and has maintained 99.5% uptime while exceeding quality targets. The compact design saved 40% floor space compared to the original concept.
Technical Specifications
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