The J74 VW Transporter All Body Shop Lines Revision Project was executed at Ford Otosan Yeniköy Plant as a comprehensive robot modernization and system upgrade program. This was not a turnkey installation, but a large-scale revision covering multiple body shop lines.

The project focused on replacing chronically problematic old-generation ABB and KUKA robots used in spot welding, sealing, and handling applications. A total of 95 industrial robots were included in the scope. The first 40 old-series ABB robots were replaced with new ABB units. The remaining 55 robots were converted from legacy KUKA/ABB systems to KUKA KRC4-based robot platforms.

All robot programs and trajectories were recreated and validated in simulation to match the previous production geometry and process logic, ensuring seamless transition without impacting dimensional quality. In-house robot systems were commissioned on site and fully integrated with existing line equipment and communication infrastructure.

The lines continue operating at a 115-second cycle time in compliance with PL-d safety standards. The project was completed within 6 months, achieving the targeted production quality levels, with 24/7 standby technical support provided during the stabilization period.