Project Description
The J74 VW Transporter Front Chassis Line was delivered as a turnkey project
for Ford Otosan Yeniköy Plant for the automated welding and sealing of the
vehicle front chassis assembly.
The system is based on Siemens S7-1500 PLC architecture and integrates a total
of 42 KUKA and ABB industrial robots for resistance spot welding and sealing
applications. The line operates at a 115-second cycle time and was digitally
validated using Siemens Process Simulate prior to commissioning.
The project scope included mechanical design and manufacturing, electrical
design with EPLAN, pneumatic design using FESTO FluidDraw365, PLC programming,
robot integration, installation, commissioning, and production ramp-up. The
project was completed within 1.5 years in compliance with PL-d safety standards,
with 24/7 technical support during stabilization.

Case Details
- Client
- Ford Otosan
- Project Type
- Turnkey Welding & Sealing Line
- Application
- Front Chassis Assembly
- Location
- Turkey
- Project Duration
- 1.5 Years
- Safety Level
- PL-d
Important Facts
- 42 industrial robots (KUKA & ABB)
- Resistance spot welding process
- Automated sealing application
- Siemens S7-1500 PLC platform
- 115-second production cycle time
- Digital validation with Siemens Process Simulate
- Electrical design with EPLAN
- Pneumatic design with FESTO FluidDraw365
- Installation & commissioning
- 24/7 technical support during ramp-up
