Vauxhall Motors

The Client

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A leading UK automotive manufacturer, Vauxhall, required an efficient solution for their engine assembly operations. The company needed a specialised conveyor system to streamline the engine block assembly process while maintaining precision and quality.

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The Challenge

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The client required a reliable and efficient system to automate the movement of car engine blocks through multiple assembly stations. Manual movement was time-consuming and created inconsistencies in the production flow. The operation required a solution that would standardise the assembly process while maintaining precise positioning at each assembly station.

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The Solution

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Central Conveyors designed and implemented a bespoke dual-tier conveyor system with the following features:

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• Top-tier conveyor specifically designed to hold engine blocks in specialised jigs

• System divided into eight separate zones for different assembly operations

• Operator-controlled progression between zones via push-button activation

• Automated return system for empty jigs

• Lower-tier conveyor acting as a storage system for empty jigs

• Full PLC control system coordinating conveyor movement and zone operations

 

The system operates through a straightforward sequence: engine blocks are lowered by crane onto the jigs at the start of the process. The conveyor then indexes the engine blocks through eight separate assembly zones. In each zone, different parts are assembled into the engine block. Operators control the progression, pressing a button once their assembly tasks are complete to move the engine block to the next zone.

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Once fully assembled, the completed engine is removed by crane, and the empty jig is automatically transferred to the lower-tier conveyor system, where it serves as storage until needed again at the start of the process.

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The Results

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The automated engine block assembly line delivered significant improvements to the client’s production operation:

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• Enhanced consistency in engine assembly, ensuring reliable quality control

• Increased throughput capacity compared to previous methods

• Reduced labour requirements, allowing staff to be deployed to other value-adding activities

• Improved ergonomics for operators with reduced manual handling requirements

• Standardised assembly sequence, reinforcing quality assurance protocols

 

The system’s durable construction and straightforward operation ensure minimal maintenance requirements, providing the client with a long-term, cost-effective solution that enhances overall production efficiency.