In April 2023, we kicked off a significant project for an Automotive North American customer at their largest factory globally, to reroute the existing conveyor line in one of their largest assembly halls.  This reroute enables the installation of batteries into their electric vehicle models, facilitating the production of their electric cars.

The project involves installing and commissioning 260 conveyors, 6 lifters, 6 turntables, 2 scissor lifts, 2 shuttles, 20 eccentric lifters, and 600 tonnes of steelwork, all within a tight five-month window from June to November 2024. The equipment and steelwork, designed to handle a 2-tonne payload, adhere to the cycle times specified in the RFQ. A highlight of this project is the Telescoping Carriage Lifter, a key component due to its heavy payload and interface with the  Shuttle—marking the customer's first Triplex chain-bed in the plant.

Our scope also included completing two production lines, Assembly Hall K and Assembly Hall M, with a focus on safety and risk assessments. The final integration into the existing line is scheduled for a five-week winter shutdown, during which we'll demolish the current line and install our equipment.

Current Progress: While we're still in the installation phase, several positive outcomes are evident:

• Pros: Exceptional steel structure fabrication, swift conveyor assembly, high-quality painting, secure skid packing, and seamless equipment installation.
• Cons: Communication gaps regarding packed items, design oversights concerning concrete installations, tight timelines, and some challenges with skid stability during shipping.

Lessons Learned: We've identified areas for improvement, particularly in standardizing equipment design for easier installation and aligning shipping manifests with actual van loads. Despite these challenges, the global automotive contender has expressed satisfaction with our work, praising our design, shipping, documentation, installation, and project planning.

We’re confident this will lead to future collaborations.