Upfront challenges faced by the assembly workers and engineers


Volkswagen Wrzesnia factory situated in Poland has been established for the manufacturing of VW Crafter since 2016. The plant is equipped with a modern paintshop, assembly section customised cars section, pilot production and supplier park, with a production capacity of 100k cars per year. The challenge for assembly workers resides in the fact that, although the crafter car only has 69 base versions, there can be as many as 99 million+ variations in customised design.


Pilot 1: The first pilot takes place in the KTL area. Car bodies, placed on skids, dive into a pool of chemicals, and through the use of electric current paint attaches to the car body. As skids are dipped into the pool many times, disturbances in their conductive properties may occur, which affect the correct completion of the KTL task, e.g., wrong thickness of the paint attached.

SHOP4CF pilot is focused on predicting and managing maintenance tasks of the skids, before faulty results on produced car bodies appear.


SHOP4CF scope:

  • Optimize the schedule and management of the workers who take care of the maintenance tasks
  • Reduce ad-hoc maintenance needs.
  • Provide more information to operators, technicians and maintenance, hence enabling more informed decision-making


Both pilot cases at VW will use knowledge extraction and intuitive programming of robots to cope with a large number of production variants. Both cases will be initially deployed in the production piloting area of the plant and later in the actual production lines.

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