AUTOMOTIVE FACTORY AUTOMATION

A comprehensive project management case study applying automation to key manufacturing workstations.

📍 Project Overview

Duration: Jan – Apr 2024
Course: Engineering Project Management – EMGT 5220
Team: A-Team – Bokka, Ruturaj, Jayendra, Kush, Mansi, Sanyam, Aayushie, Bharath
Role: Planning, Strategy, Budgeting, Execution & Risk Management

This project proposes the automation of an automotive factory’s welding, painting, windshield assembly, and tire installation workstations to eliminate production inefficiencies, improve quality, and optimize safety. It demonstrates end-to-end application of project management practices from initiation to closure.

🚘 Challenges in Traditional Setup

• Manual MIG welding caused inconsistencies and material waste

• Paint jobs lacked uniformity and posed health risks

• Windshield and tire assemblies were prone to misalignment and rework

• Industry-wide labor shortages and skill gaps further strained operations

🤖 Automation Solution

• 6 Yaskawa robots installed for precision MIG welding

• 6 FANUC robots deployed for consistent paint coverage

• 3 robots for automated windshield gluing and placement

• 3 robotic arms for tire alignment and bolting with pneumatic guns

The integration was engineered to align with the existing conveyor system to minimize civil modifications and maximize ROI.

📊 Project Management Approach

• WBS: 4 key phases – Initiation, Planning, Execution, Closure

• Tools: RACI Matrix, Gantt Chart, Risk Register, Cost-Benefit Analysis

• Control Room with SCADA dashboard for centralized monitoring

• Standard Operating Procedures (SOPs) and training post-installation

📈 Business Impact

• Targeted 20% reduction in manufacturing costs

• Expected 30% gain in task efficiency

• Improved safety with projected 72% reduction in incidents

• Profit margin projected to rise to 8.5% by FY2026

📅 Timeline & Budget

• Timeline: 556 days (Mar 2024 – May 2026)
  Total Budget: ~$26 million
  Break-even: Expected by FY2035 based on efficiency savings and throughput growth

🛠 My Role

• Contributed to budget planning and stakeholder reporting

• Participated in risk identification and mitigation strategies

• Assisted in WBS design and process flow validation

• Co-drafted final report and audit frameworks

📎 Key Documents

• Final Report | WBS Chart | Gantt Schedule | Risk Register | Budget Overview

💭 Reflections

This was a true capstone experience — taking a hypothetical yet complex factory setup and applying real-world project management tools to redesign it through automation. It pushed us to collaborate, evaluate risk, plan resources, and build processes that reflect actual industry standards.