Improving Reliability of an Automotive Robotic Assembly Workstation through Mechanical Redesign and Automation Optimization

Abstract

The increasing level of automation in the automotive industry has significantly improved manufacturing productivity, product quality, and operational consistency. However, highly automated production systems require efficient maintenance strategies to ensure equipment availability and minimize production downtime. This study presents a technical approach for reducing maintenance costs and improving the operational reliability of an automotive product assembly line. The research focuses on one workstation, identified as the critical bottleneck due to its high maintenance expenses, extended downtime, and repeated failures of a collaborative robotic system responsible for the screw-tightening operation. A systematic engineering analysis was performed to identify the principal causes of equipment failures, evaluate workstation functionality, and assess the impact of maintenance-related interruptions on production efficiency. Based on the obtained results, one technical solution is proposed: the replacement of the existing collaborative robot with a more suitable robotic solution capable of supporting the operational requirements of the assembly process. The proposed improvements are evaluated from both technical and economic perspectives. The results demonstrate a significant reduction in maintenance interventions, equipment downtime, repair costs, and production losses while increasing workstation availability and overall manufacturing efficiency. The study highlights the importance of integrating mechanical redesign and automation optimization into predictive maintenance strategies for modern automotive manufacturing systems.