Automation
Built for precision. Driven to outperform.
Automation drives modern automotive manufacturing by integrating robotics, PLCs, machine vision, and industrial IoT to streamline operations, cut errors, and ensure consistent quality. Robots weld, paint, assemble, and move materials faster and more precisely than manual labor, keeping high-volume lines running with less downtime. Real-time data enables predictive maintenance, preventing breakdowns and extending equipment life.
Beyond efficiency, automation increases flexibility for rapid model changes and safeguards workers by removing them from hazardous or repetitive tasks. This strategic capability supports innovation, competitiveness, and the industry’s pivot toward electric vehicles, smart factories, and sustainable practices—cementing automation’s role in the future of automotive production.
Lineside specialists have combined decades of experience in stamping controls, including:
Lineside recently completed a comprehensive controls modernization for a major automotive OEM’s mechanical transfer press—revitalizing critical production equipment with improved safety, diagnostics, and reliability.
Scope of Work
We replaced a legacy Yaskawa PLC with a modern Allen-Bradley GuardLogix platform, upgraded PanelMate HMIs to robust Pro-Face interfaces, and transitioned outdated hardwired safety systems to integrated GuardLogix safety control—bringing the press into compliance with today’s industrial safety standards.
Hardware & Software Highlights
Results at a Glance
This controls upgrade ensures long-term supportability, reduces downtime, and positions the transfer press for future automation and data integration.
Lineside specialists have combined decades of experience in welding controls, including:
Project Spotlight: Weld Cell Cycle Time Optimization for an Automotive Tier 1 Supplier
Lineside partnered with a leading automotive Tier 1 supplier to reduce weld cell cycle time by optimizing its control architecture—delivering tangible gains in productivity without major hardware changes.
Scope of Work
Our team conducted a detailed analysis of the existing sequence logic, interlocks, and robot handshaking. We then reprogrammed the cell using efficient PLC logic, implemented parallel processing, and fine-tuned the robot-PLC communication timing. Minor HMI enhancements were also made to improve operator interaction and reduce unnecessary delays.
Hardware & Software Highlights
Results at a Glance
This project is a strong example of how smart programming and detailed analysis can drive significant efficiency gains—extending equipment life and improving throughput with minimal investment.
Lineside specialists have combined decades of experience in paint controls, including:
Our team recently delivered a turnkey robotic wax application system for a global automotive OEM, transforming a manual, ergonomically challenging process into a fully automated, high-precision operation. The project featured six collaborative robots (cobots) equipped with 3D vision and adaptive wax dispensing tools, enabling precise, model-specific cavity coverage without the need for mechanical retooling or safety fencing.
Additional Hardware / Software Highlights
Robotics: Six collaborative robots with integrated safety for human interaction
Vision: Real-time 3D vision sensing for vehicle cavity mapping
Dispensing: Adaptive end-effectors calibrated to vehicle geometry
System Design: Redundancy and predictive diagnostics for >99% uptime
Results at a Glance
30% reduction in cycle time
Uniform wax coverage and improved corrosion protection
Significant reduction in material waste and operator strain
Fast reprogramming for new vehicle models
This fully integrated solution set a new benchmark in precision and safety for wax application, combining intelligent automation with ergonomic design for long-term efficiency and adaptability.
Lineside specialists have combined decades of experience in assembly controls, including:
Our team recently completed a full safety and controls modernization project for an automotive OEM’s vehicle lifter systems. The project involved replacing legacy Allen-Bradley PLC5 controllers with modern GuardLogix platforms and upgrading outdated PanelMate HMIs to user-friendly PanelView Plus interfaces. We also integrated advanced safety features, including light curtains, area scanners, emergency stop buttons, and Safe Torque Off (STO) functionality.
Additional Hardware / Software Highlights
PLC: Allen-Bradley GuardLogix with integrated safety control
HMI: PanelView Plus for improved diagnostics and system visibility
Safety: Light curtains, area scanners, and STO for comprehensive operator protection
Results at a Glance
40% reduction in mean time to repair (MTTR)
Fully compliant with ISO 13849-1 and ANSI/RIA R15.06 safety standards
Enhanced system uptime and simplified maintenance
This turnkey upgrade not only improved safety and reliability but also positioned the lifter systems for future expansion and Industry 4.0 integration.
Lineside specialists have combined decades of experience in facilities controls, including:
Project Spotlight: Air Handling System Optimization for an Automotive OEM
Lineside recently helped an automotive OEM optimize their facility’s air handling units (AHUs) by integrating variable frequency drives (VFDs) and implementing a dynamic control schedule—resulting in major energy savings and better environmental control.
Scope of Work
We retrofitted existing AHUs with Allen-Bradley PowerFlex VFDs, enabling precise fan speed control based on real-time demand. Our team developed a dynamic scheduling algorithm that adjusted airflow based on production schedules, occupancy, and ambient conditions. The control logic was deployed on a central PLC with visibility through the building’s SCADA interface.
Hardware & Software Highlights
Results at a Glance
This facilities upgrade proves how smart automation and demand-driven control can lower operating costs and support sustainability goals—without compromising comfort or production needs.
Automation reduces downtime in automotive plants through predictive maintenance, real-time monitoring, and early fault detection. By identifying issues before they cause failures, it minimizes unplanned stoppages and extends equipment life.
Automated scheduling and performance insights also improve maintenance efficiency, helping manufacturers maintain high productivity and lower costs.
Automation enhances quality control by ensuring consistent, precise processes and reducing human error through real-time detection with vision systems, sensors, and AI tools. Continuous data logging and analysis help identify trends, enabling quick corrective action and ongoing process optimization.
This minimizes waste and rework, ensures compliance with industry standards, and supports high product reliability and customer satisfaction.
Automation improves safety in automotive manufacturing by reducing human exposure to hazardous tasks, environments, and repetitive strain. Robots handle high-risk operations like welding, stamping, and material handling with precision, while built-in safety systems detect anomalies and enforce emergency protocols.
This creates a safer, more controlled work environment, lowering injury rates and allowing employees to focus on supervision and oversight.
Automation enables fast adjustments to production volume and vehicle variations, providing the scalability and flexibility needed in modern automotive manufacturing. Technologies like PLCs, robotics, and modular systems allow quick reconfiguration with minimal downtime, helping manufacturers respond to changing demand and shorten lead times.
This adaptability supports lean manufacturing by reducing waste, optimizing resources, and maintaining consistent, efficient output in a competitive environment.
