There is no room for error in a vehicle production plant. Every movement of a robot, every step in an assembly sequence and every second in a work cycle obey a perfectly designed logic. In a sector where every second counts (one cycle could last just 51 seconds) any deviation can lead to cost overruns, delays and disruptions in the supply chain. That is why starting up an assembly line requires meticulous planning that can guarantee a smoothly running system that complies in every way with technical requirements.
At Aritex, a project for the automobile sector can mobilise over a hundred professionals; engineers who specialise in mechanics, electricity, automation and programming, all working together to make pinpoint accuracy a reality.
To better understand how a project like this takes shape, we spoke to Miquel Julián, Head of Project Engineering at Aritex. He took us through the stages that can make an idea turn into a fully operational, highly accurate production line, from the initial proposal to final start-up.
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From first specifications to a technical solution
Developing an engineering project tailored to the automobile sector at Aritex has its own structured sequence where every phase directly connects to the next one. The process starts with a technical-economic proposal, which, once approved, leads onto detailed design of the production process. According to Miquel, “some clients tell you about the product they want to make and some basic parameters such as the cycle time or the number of operators; some, on the other hand, give you precise details about the solution they want, from the type of robot to the functioning logic. Whatever the case, we’re dealing with extremely strict standards”.
A key factor at this stage is advance purchase of critical components, where market availability can have an effect on project deadlines. Detecting these materials right from the start ensures that they arrive on time and prevent delays in manufacture or installation.
After purchasing, the process continues with manufacturing the tools and structures, followed by control software development for the robots and programmable logic controllers. The culmination of this process is when the line is installed and commissioned in the plant.
Although installing a line in a plant is a major technical achievement, the real challenge comes shortly after, in the fine-tuning phase. This stage involves checking the system’s behaviour under real-work conditions, ensuring that the robots are synchronised, trajectories are calibrated and cycle times are tuned to pinpoint accuracy. All this happens while the client supplies the necessary parts and validates each individual part of the system’s functions.
The time between the contract award and the initial assembly is usually about six months, but the validation phase can extend the time spent on the project to over a year, given that it is an essential period for optimising the system under real conditions. “These adjustments can be extended over time if the client changes specifications or delays deliveries of parts”, says Miquel. In his opinion, the vital thing at moments like these is a flexible attitude within the team. “We anticipate potential risks or deviations and quickly report any change that might have an effect on how the project develops. Although there are factors that do not directly depend on us, such as delays to the building where the system is being installed or repeated product changes, Aritex always responds with a flexible attitude. Our capacity to adapt means we can accompany the client through every adjustment, offering solutions that impose no penalties on the rhythm of the project”.
Advanced simulation and virtual commissioning
In the automobile sector, especially in body-in-white stage, simulation goes hand in hand with the project right from the initial mechanical design. The line is conceptualised and the mechanics are validated in the office: the elements are located in space, cinematic movement is assigned and factors such as the robots’ capacity to enter and leave the tools are verified.
“Simulations start in the concept phase: we validate the mechanical layout and the robots’ trajectories”, explains Miquel. “Then we generate a complete 3D model, which we use to test all the system logic, including the programmable logic controller, in a virtual environment. This approach enables the software to be refined before reaching the plant; it also reduces the number of personnel on site and prevents errors and cost overruns”.
After the simulation and while the mechanical installation continues at the plant, work continues at the office with virtual commissioning, a virtual start-up that integrates programming the robots and the PLC. The process includes controlling the opening and closing of tools, safety systems and all the logic necessary for the line to function as a whole. The phase enables the entire system to be digitally tested and refined; it also ensures that when the equipment reaches the plant, the programming will be ready to operate with minimal intervention and tuning.
But the simulation is not just limited to robots and machines. It also involves ergonomic studies in the spaces where robots interface with employees on the line. “We run simulations of robots and ergonomic studies in areas where operators handle parts, assessing aspects such as the height and positioning of the arms to guarantee comfort and meet European standards”.
The flow of materials is also analysed to identify deficiencies in each area, while time estimates are run to see how long a line can be stopped to determine the optimal number of parts to be accumulated within the process. The aim here is to ensure that the process keeps up a constant rhythm, ensuring that the flow will continue uninterruptedly even when a line is stopped for five minutes due to a robot failure.
Choosing one type of software or another (e.g., NX, CATIA, Process Simulate, RF Suite and Plant Simulation) is often a response to the needs of the engineering team, but such a decision also takes into account the standards and preferences of each and every client, yet another factor that highlights the technical and operational flexibility of the team at Aritex.
The results show just how effective the process is. Miquel mentions a project that achieved a cycle time of 51 seconds almost from the first attempt thanks to the highly precise virtual environment. On another occasion, all the programming was completed in the office, which enabled fast and flexible deployment and reduced on-site tuning to a minimum.
The power of a multidisciplinary team
Inter-departmental collaboration is vital. “We in the engineering division work hard to ensure that all the areas —mechanics, electrical, software, simulation— are fully aligned right from the start. Without an adequate communication, serious errors can arise. For example, if someone designs an electrical diagram and does not share criteria with the person who programs the system, the software may not function the way it is expected to. The same thing can happen with the layout: if the elements are distributed in a particular way and then another layout is used in the simulation, incompatibilities can arise when on site. That is why we foster integrated work from the very beginning”, says Miquel.
Aritex has technical teams strategically distributed around the world. Mexico in particular has a team of 20 mechanical design specialists with a lot of experience in the automobile sector. At the same time, the headquarters in Badalona is home to a team of 30 professionals who coordinate, validate and supervise the project to guarantee the highest quality in what we do.
In electrical engineering, our own team of five engineers works on designing electrical diagrams using ePlan, which enables them to directly control materials purchasing, improve planning and flexibly adapt to changes. “This way we can purchase electrical materials in advance, and that enables us to move fast, be more flexible in the electrical management side of the project and boost our competitiveness”, says Miquel.
To ensure process continuity, Aritex applies a collaborative methodology based on constant and fluid communication. Project planning includes weekly meetings, regular reviews and internal validations to detect any deviations in real time.
The team’s global structure also provides a competitive advantage: “Time zone differences between our offices enable us to optimise response times. If a client proposes a change at the end of the working day in Spain, the team in Mexico can work on developing it during their working hours. Then the next day we have a solution ready for validation”.
Engineering as a commitment and as a responsibility
According to Miquel, “engineering implies responsibility, a strategic vision and a capacity to adapt to the unexpected”. At Aritex, this philosophy is expressed in careful planning, cross-functional collaboration, well-structured engineering, a global vision and exhaustive control of all the variables. “We have a multidisciplinary team with a huge experience in mechanics, electricity, automation and software. This in-depth knowledge means that deliverables are solid, consistent and up and running according to schedule, which generates trust amongst our clients and makes the difference in every project”, he says.
