Reducing Downtime in Electric Vehicle Manufacturing with Adaptive Robotics

Summary

A leading electric vehicle (EV) producer needed support standing up operations at a Manufacturing Center (MC). When the project first kicked off in 2021, the MC’s production floor featured a quarter-mile MangeMotion conveyor system and a series of large Fanuc robots capable of moving electric-vehicle components through the production line.

Many of the client’s site operators and in-house engineers were unfamiliar with MagneMotion, and even though the Fanuc robots were programmed by a different OEM, they were ineffective and would break down during cycle interruptions. As a Rockwell Automation Gold System Integrator and MagneMotion expert, DMC was brought on-site to audit and optimize the production line, with a focus on reducing system downtime, diagnostics, and enabling the client’s operators to scale and sustain production long after the project concluded.

Solution

DMC took a multifaceted approach to improve operations at the client’s manufacturing site, beginning with an audit of the existing tech stack and advancing to reprogramming their Fanuc robots for greater adaptability. The updated controls logic enabled dynamic decision-making during production interruptions, while decision trees on the site’s HMIs improved operator guidance and diagnostics. Following deployment, DMC also equipped the client’s team with the knowledge and support needed to sustain and scale operations.

Reviewing the Client’s Existing Tech Stack

DMC began by auditing the client’s existing hardware, including the MagneMotion conveyor system, Rockwell HMIs, and Fanuc robots, as well as software tools, including the robots’ initial programming language and decision logic, to identify system limitations, integration challenges, and opportunities for improvement. This assessment informed a strategy to enhance system flexibility, reliability, and readiness for future expansion.

Reprogramming and Modular Logic

The site’s Fanuc robots needed to be more dynamic and capable of making logical decisions to balance material flow through the Manufacturing Center. DMC reprogrammed the client’s Fanuc robots to be able to make real-time decisions when their production cycles were interrupted. This modular approach to robotics logic improved system resilience and allowed each robot to respond intelligently within its portion of the process.

Decision Tree and Operator Prompts

DMC developed decision-tree logic and embedded operator prompts within the HMIs throughout the site to support scalability and greater troubleshooting. These features prompted operators through key decision points during system interruptions or crashes, streamlining diagnostics and reducing downtime.

Knowledge Transfer and Ongoing Support

After integrating the updated systems across the Manufacturing Center, DMC worked closely with the client’s operations team to transfer knowledge and ensure a smooth transition. Ongoing support was provided to help the client adapt to evolving manufacturing and production needs, ensuring long-term success and scalability.

Result & Conclusion

As a trusted leader in manufacturing automation, DMC routinely supports clients with large-scale manufacturing operations to improve controls systems, develop functional specifications, and provide on-site services, supporting and optimizing key steps of production cycles.

For DMC’s EV producer client, the team leveraged every area of their manufacturing automation expertise to build a resilient system capable of adapting in real time to production interruptions, reducing system downtime from 90 minutes to less than 30 minutes. In addition to greater operational efficiency, DMC also worked closely in person with our client’s operations team, teaching them how to effectively use the modular control logic and engage with HMI prompts.

Through knowledge transfer and ongoing support, the client gained the tools to sustain and scale operations, positioning the Manufacturing Center for long-term growth.