General MotorsCase study · Robotics & Automation
Robotic Final Line Automation
Turning a manual final line into a robotic process for doors, hoods, fenders, and hinges.
- My role
- Controls Engineer
- Timeframe
- General Motors · Oct 2023 – Present
- Team / context
- General Motors, Warren, MI
- Tech stack
- New-to-industry robotics · Atlas Copco bolt runners · Bolt and U-nut feeders · Net form and pierce · Variation-reduction cameras · PLC
01
Overview
Final line operations that install doors, hoods, fenders, and their hinges were being done manually. I'm automating that line with new-to-industry robotics.
The robots are only part of it. The line combines best-fit Atlas Copco bolt runners, bolt and U-nut feeders, net form and pierce, and variation-reduction cameras that measure gap and flush, all working as a single automated process.
02
The problem & objective
The line was manual. Doors, hoods, fenders, and door and hood hinges were assembled by hand.
These are some of the most visible parts of a vehicle, where gap and flush define perceived quality. The objective was to automate the assembly while building quality measurement into the process.
03
My role & responsibilities
Controls Engineer. Delivered as part of my role as Controls Engineer at General Motors.
- Automate the manual final line with new-to-industry robotics
- Integrate best-fit Atlas Copco bolt runners and bolt and U-nut feeders
- Integrate net form and pierce
- Integrate variation-reduction cameras for gap and flush
- Test, validate, and audit the automation against throughput and quality targets
- Update PLC logic for approved changes
- Drive supplier deliverables and buyoff checklists, and track open issues to closure with leadership
04
Approach & process
Scope the operations
Assembly of doors, hoods, fenders, and door and hood hinges, the operations being moved from manual to robotic.
Select best-fit equipment
Atlas Copco bolt runners, bolt and U-nut feeders, and net form and pierce tooling, chosen to fit the process.
Build in measurement
Variation-reduction cameras measure gap and flush, so fit and finish are checked within the process.
Validate against targets
Test, validate, and audit the automation against throughput and quality targets, updating PLC logic for approved changes.
Drive suppliers to buyoff
Manage supplier deliverables and buyoff checklists, and track open issues to closure with leadership.
05
Key features & deliverables
Robotic assembly
New-to-industry robotics assembling doors, hoods, fenders, and door and hood hinges.
Automated fastening
Best-fit Atlas Copco bolt runners fed by bolt and U-nut feeders.
Net form and pierce
Forming and piercing integrated into the automated process.
Gap and flush measurement
Variation-reduction cameras measuring gap and flush.
06
Challenges & how I solved them
| Challenge | How I solved it |
|---|---|
| New-to-industry robotics has no established playbook | I rely on rigorous testing, validation, and auditing against throughput and quality targets. |
| Many technologies must act as one process | I treat the robots, fastening, feeders, forming, and cameras as one integrated system, and control logic changes through approval. |
| Multiple suppliers, one schedule | Buyoff checklists and issue tracking with leadership keep each deliverable verifiable and every open item owned. |
07
Results & impact
- Automating a previously manual final line with new-to-industry robotics
- Gap and flush measured inside the process by variation-reduction cameras
08
Skills demonstrated & lessons learned
Skills demonstrated: Robotics integration · Fastening and feeder systems · Machine vision for quality · PLC programming · Validation and buyoff · Supplier management
With new-to-industry equipment, validation discipline matters more than ever because there's no prior line to compare against.
Get in touch
Let's work together
I'm open to Controls Engineer, Automation Engineer, Software Engineer, and Full-Stack Developer roles, remote or on-site. If you're building something where automation and software meet, I'd like to hear about it.
elshark.atef@gmail.com