As detailed by Assembly Magazine in their article “Conveyor-Less Micro Factories for Urban Car Production,” the automotive industry is shifting from mass customization to mass individualization, driven by consumer demand for highly personalized vehicles. This trend, accelerated by the rise of autonomous electric vehicles (AEVs), necessitates a new approach to car manufacturing—one that emphasizes flexibility and decentralization.

The Urban Micro Factory Model

Traditional automotive manufacturing involves centralized facilities where press shops, paint shops, and assembly lines are housed together. However, this model struggles to support low-volume, high-mix production needed for personalized vehicles. Urban micro factories present an innovative solution by decoupling final assembly from mass production. Key advantages include:

• Location Flexibility: Final assembly can be carried out in smaller urban spaces where labor supply is more elastic.
• Reduced Space Requirements: Eliminating fixed conveyor lines enables factories to fit in compact locations such as warehouses.
• Improved Customization: Micro factories allow automakers to quickly adapt production to unique customer preferences.

Examples of Urban Micro Factories

1. Arrival’s Micro Factory (Rock Hill, SC): This facility assembles electric buses and vans using aluminum frames and composite body panels. By avoiding traditional metal-stamping presses and conveyor lines, the factory was set up in an existing warehouse in just six months.
2. e.GO Mobile (Aachen, Germany): Designed to minimize environmental impact, this factory employs quiet operations and strategic logistics to avoid disrupting surrounding residential areas.
3. Volkswagen’s Transparent Factory (Dresden, Germany): Opened in 2001, this factory uses public trams to transport materials, reducing traffic and emissions.
4. Hyundai Mobility Global Innovation Center (Singapore): This smart factory emphasizes sustainability and integration with urban infrastructure.

Key Technologies Enabling Conveyor-Less Production

To replace conveyor systems, micro factories rely on advanced autonomous transport technologies:

• Autonomous Mobile Robots (AMRs): These vehicles navigate the assembly floor using onboard sensors without magnetic tracks, enabling flexible routing.
• Vehicle-as-a-Conveyor (VaaC): The EV itself guides its movement through the assembly process via a sensor skid temporarily attached to its underbody. The skid communicates with a fleet management system and can be easily removed after assembly.
• Vehicle-Powered Positioning Devices: Instead of external lifts, these devices use the vehicle’s own motion to adjust its height during assembly, reducing power consumption and saving space.

Future of Car Manufacturing

The combination of urban micro factories and asynchronous production systems could lead to point-of-sale factories within car dealerships. In this scenario, components such as the chassis, body, and interior elements are shipped directly to the dealership, where the vehicle is assembled and delivered to the customer. This model offers significant potential for faster order-to-delivery times and highly customized vehicle options.

Click here to learn more about May Conveyor’s capabilities and products.

Article with all rights reserved, courtesy of assemblymag.com.