Automation and robotisation in the automotive industry

The automotive industry does not forgive errors, and every second of delay on a Tier 1 or OEM production line is a measurable financial loss and a risk of contractual penalties.

At MDP Engineering we design, build and commission turnkey automated assembly lines as well as robotic welding and inspection cells. We deliver solutions that stabilise processes, hold a strict takt time and meet the highest quality standards, supporting plants in compliance with requirements such as IATF 16949.

Production challenges for Automotive (Tier 1, Tier 2, OEM)

Working with automotive parts suppliers, we understand their challenges:

Unforgiving takt time

Automotive lines run Just-in-Time / Just-in-Sequence. A delay in one operation disrupts the supply chain for the final vehicle manufacturer.

High cost of mistakes (scrap rate):

Faulty assembly of components (headlamps, drivetrains, electronics, interior modules) leads to costly claims. This requires 100% inspection and poka-yoke on the line.

Complex changeovers (SMED) and e-mobility (EV):

New EV platforms and frequent facelifts need flexible machines that can be changed over quickly and cheaply to another part number.

Brownfield integration:

Modernising live halls, where a new robotic station must plug into an existing conveyor and infrastructure without long stoppages of neighbouring lines.

Our engineering solutions: why MDP Engineering for automotive?

For the automotive production engineer and plant manager we are a partner who delivers technical substance and understands the cost of downtime.

Robotic workstations and assembly lines in automotive

Repeatability of manual operations is not enough. We design robotic workstations that automate the heaviest processes, guarantee a constant takt and eliminate human error (0 ppm).

Deploying a robot on bearing press-fit, seal dispensing or body-in-white welding immediately improves OEE. We remove micro-stops and get identical parts in every batch.

We integrate industrial robots and cobots such as Fanuc. 2D and 3D vision on the robot wrist corrects paths live and inspects gap and flush or part presence.

Ausführung von Roboterstationen einschließlich Inbetriebnahme

PLC programming and full traceability

We know OEM specifications (e.g. VAG group standards). We write safe, fast PLC software on proven architectures such as Siemens TIA Portal.

Integration benefit:

Full traceability. Sensor measurements, leak-test sequences and torque from transducer screwdrivers are collected by the PLC and sent to your MES.

HMI screens are built for fast alarm diagnostics for Maintenance, so faults do not drag on.

Digital Twin and Virtual Commissioning: fast start-up without stopping the plant

Revamping in automotive carries a huge downtime risk. This is our main differentiator. Instead of experimenting on the shop floor we use Virtual Commissioning and a Digital Twin, e.g. in Siemens NX / Process Simulate.

What you get?

Before we assemble the cell physically we build a virtual replica. We run PLC code digitally, optimise Fanuc paths and measure takt. Kinematic faults are found on a computer, not on steel.

Value of Virtual Commissioning

When we arrive in a short weekend window, machine software is already tested. Commissioning time often drops by about 70%, without jeopardising Monday production.

3D scanning of halls and reverse engineering in automotive

Missing up-to-date layout documentation at a Tier 1 is everyday reality. With 3D scanning we capture a point cloud of your hall fragment and conveyors. The new robotic station is designed into that envelope — plug-and-play assembly, fewer unplanned modifications. Reconstructed parts can be machined by sister company MDP Precision.

Turnkey process: from concept to FAT/SAT

As a turnkey specialist we take sole responsibility for the investment:

  1. Analysis, concept and solution selection: OEE calculation, safety concept review.
  2. Design (3D CAD, SolidWorks, EPLAN): Complete mechanical and electrical documentation to automotive standards.
  3. Simulation (Digital Twin): Digital twin and robot-path optimisation.
  4. Build (FAT): Tests on our shop floor with the client’s engineers.
  5. Commissioning (SAT) at the client: Fast installation thanks to virtual commissioning, calibration and production launch.
  6. Maintenance support: After-warranty help and certified procedures under ISO 9001:2015.
rysunki techniczne

Why choose MDP Engineering?

Experience and expertise
Our team has extensive experience in PLC programming for various industrial sectors, including defence and aerospace, where the highest standards of quality and safety are required.

Modern technologies
We work with current standards and tools such as Siemens Step7 and TIA Portal, as well as programming languages compliant with IEC 61131-3 (Ladder Logic, Structured Text).

Individual approach
We tailor solutions to the client’s specific needs and budget, delivering optimal results.

Comprehensive service
From design through integration and testing to training and after-sales support.

Discuss your automotive project with an engineer

There is no room for compromise in automotive automation. Talk to an MDP Engineering engineer who understands your plant architecture and OEM/Tier 1 RFQ specifications.