Multi-Reference Assembly Line for Accelerator Pedal | Case Study

The customer needed a multi-reference assembly line for accelerator pedal production, capable of maintaining a 6.5-second cycle time across multiple product variants.

The key challenge was not only the required production speed, but also the variability of the process itself. The line had to handle frequent product changes while maintaining repeatability, short changeover times, and stable overall performance.

Additional complexity resulted from the need to integrate multiple subsystems into one reliable process, including robotics, FIMOTEC / MAFU feeding systems, and end-of-line testing. The project also had to account for variable quality and availability of customer-supplied components, which directly affected process stability.

We designed and implemented a multi-reference assembly line optimized for repeatability, flexibility, and stable cycle performance across all product references.

The solution included:

• optimization of the overall process sequence to reduce unnecessary motion and improve cycle efficiency,
• tuning of robot trajectories to support repeatable and stable operation at the required takt time,
• redesign of the component feeding concept to improve consistency across changing product variants,
• stabilization of feeder performance through mechanical and software modifications,
• implementation of multiple mechanical and automation improvements to increase process robustness,
• close cooperation with the customer during commissioning, enabling fast adaptation to product changes and process-related issues.

The line was designed not only to achieve the target cycle time, but also to remain stable under real production conditions, where variability and changeovers are part of daily operation.

During implementation and commissioning, the project demonstrated:

• stable achievement of the required 6.5-second cycle time across all references,
• technical availability above 95%,
• reliable cooperation between robotics, feeding systems, and EOL testing,
• improved cycle repeatability through process and motion optimization,
• stable operation despite frequent product changes,
• readiness for high-volume serial production.

The implemented solution enabled:

• achievement of the required cycle time for all product variants,
• technical availability above 95%,
• short changeovers between references,
• high assembly quality and improved process repeatability,
• a stable and flexible line ready for serial production,
• capacity for the production of millions of units per year.

The project delivered value beyond cycle time achievement alone. It enabled the customer to operate a multi-variant production process with greater predictability and lower risk of disruption. By improving the stability of component feeding, process logic, and subsystem integration, the line became more robust and better suited for daily production changes.

Key business benefits included:

• reduced risk of downtime,
• improved line efficiency,
• better handling of product variability,
• faster response to changing production requirements,
• a scalable production concept prepared for long-term serial manufacturing.

This project confirmed that maintaining a 6.5-second cycle time in multi-reference production is possible, provided that the process is designed as a complete, stable system.

In this case, success depended not only on robotics, but on the combination of optimized process logic, reliable component feeding, effective subsystem integration, and repeatable cycle execution. The result was a stable and flexible assembly line ready for demanding automotive serial production.