• Skip to primary navigation
  • Skip to main content
  • Skip to primary sidebar
  • Skip to secondary sidebar
  • Skip to footer
  • Home
  • Subscribe
  • Your Membership
    • Edit Your Profile
  • Services
    • Advertising
    • Case studies
    • Design
    • Email marketing
    • Lead generation
    • Magazine
    • Press releases
    • Publishing
    • Sponsored posts
    • Webcasting
    • Webinars
    • White papers
    • Writing
  • Shop
    • My Account
    • Cart
  • About
    • Contact
    • Privacy
    • Terms of use
  • Events

Robotics & Automation News

Market trends and business perspectives

  • News
  • Features
  • Sections A-Z
    • Agriculture
    • Aircraft
    • Artificial Intelligence
    • Automation
    • Autonomous vehicles
    • Business
    • Computing
    • Construction
    • Design
    • Drones
    • Economy
    • Energy
    • Engineering
    • Environment
    • Health
    • Humanoids
    • Industrial robots
    • Industry
    • Infrastructure
    • Investments
    • Logistics
    • Manufacturing
    • Marine
    • Material handling
    • Materials
    • Mining
    • Promoted
    • Research
    • Robotics
    • Science
    • Sensors
    • Service robots
    • Software
    • Space
    • Technology
    • Transportation
    • Warehouse robots
    • Wearables
  • Video
  • Webinars
  • White papers
  • Press releases
  • Featured companies
    • AMD Xilinx
    • BlueBotics
    • Elite Robot
    • RGo Robotics
    • SICK Sensor Intelligence
    • Vicor Power

Comau supplies robotic systems for 20 Alfa Romeo manufacturing lines

November 19, 2022 by Mark Allinson Leave a Comment

Comau has designed and deployed a flexible body-in-white (BIW – a car body) manufacturing solution for the all-new Tonale (pictured below), the first Alfa SUV of the new generation, meeting both the customer’s rigorous production targets, quality goals and time to market objectives.

The new and enhanced 20 lines are designed to allow the automaker to assemble its mid-size Tonale in a random mix of up to 4 different versions while maintaining the desired throughput.

Fully scalable, the innovative solution lets the automaker produce multiple brands on the same line whileallowing them to further expand production in the future if and when it is needed.

Moreover, Comau’s ability to execute the entire project to deliver maximum quality in terms of processes and production equipment, has allowed the joint project team to ensure the value of the final product while fully meeting the stringent requirements of a premium brand such as Alfa Romeo.

Tasked both with building five completely new lines and retooling 15 existing lines to accommodate the new Tonale, Comau deployed the production lines in record time despite multiple challenges.

The SUV chassis is significantly larger than the compact car for which the line was originally designed, and Comau was asked to make the necessary changes without sacrificing production of either vehicle.

Through simultaneous engineering, the team designed a transformation strategy that allowed Comau to execute the retooling operation in parallel with the existing activities, according to its “Zero Loss Launch” philosophy. Comau also worked on the lines during the plant’s natural downtime, thus minimizing any impact on production.

As part of Comau’s lean manufacturing approach, the automated and semi-automated production solution is based on the proprietary ComauFlex technology, nicknamed Butterfly due to its impressive agility and use of suspended robots.

This set-up allows Alfa Romeo to change or modify a specific vehicle model by adjusting the robot tooling, not the arrangement of the robots themselves.

In addition to protecting the scalability of the customer’s initial investment, the solution is designed to enable the introduction of new models in the future for a fraction of the initial expenditure.

Indeed, the entire system features 468 welding robots, 148 of which are completely new and 320 taken from existing lines. Comau utilized advanced simulation tools during the entire development period, guaranteeing the best quality product and throughput.

In addition to allowing Alfa Romeo to perform the complex bodyshop processes with extreme precision, the Comau-designed solution fully assembles the entire BIW from start to finish.

With the aid of three different vision systems to aid the automated picking and positioning of pieces, the robots weld, fasten and perform other activities, including the spreading the semi-structural adhesive on the parts and plasma cutting during the end-of-line activities.

All said, the process involves the insertion of roughly 2,800 welding spots for each model.

With significant net output, Alfa Romeo can bank on substantial savings in terms of time, long-term costs and production efficiencies.

Moreover, because the solution is a fully modular system built around standard products that are combined within an expandable design framework, the automaker can quickly expand its manufacturing environment with limited impact on existing production.

Pietro Gorlier, Comau CEO, says: “To join forces with a prestigious brand such as Alfa Romeo is an incredible opportunity to develop cutting edge technologies and we are proud to see the tangible results of Comau’s field-proven expertise within the collaboration between two Italian examples of excellence.

“Our commitment to unwavering quality is seen within the processes and products used to make the Tonale, and allow us to ensure maximum value for the customer.”

Andrew Lloyd, Comau chief of engineering, says: “In supporting the Alfa Romeo brand in their product expansion, Comau has fully leveraged its longstanding experience in automation and smart manufacturing to deliver an unprecedented level of flexibility.

“This innovative approach to implementing brand new technologies and retooling existing lines and equipment is a direct result of our commitment to offer increasingly scalable and sustainable solutions, helping our customers better meet their objectives today as well as tomorrow.”

Print Friendly, PDF & Email

Share this:

  • Print
  • Facebook
  • LinkedIn
  • Reddit
  • Twitter
  • Tumblr
  • Pinterest
  • WhatsApp
  • Telegram
  • Pocket

You might also like…

Filed Under: Features, Manufacturing Tagged With: activities, alfa, automaker, brand, comau, customer, designed, entire, existing, fully, lines, manufacturing, processes, product, production, quality, retooling, robots, romeo, solution, time, tonale

Join the Robotics & Automation News community

Reader Interactions

You must log in to post a comment.

Primary Sidebar

Latest articles

  • VanceAI Art Generator Guide: Create Visuals in Few Steps
  • VanceAI Photo Editor Can Ease Your Workflow
  • Mastering Time Tracking: How to Properly Utilize Simple Time Clock Software
  • What are the key benefits of website visitor detection tools?
  • What Does a Switch Do in a Network?
  • The Best Rust AK-47 Skins in 2023
  • Palletizing Systems and Robots
  • Exchange vs OTC: Deciphering the Best Fit for Large Volume Crypto Trades
  • Legal Remedies: Tips for Affected Employees in Overtime Pay Violations
  • Zendesk Data Migration Made Simple: Explore Options Available

Most Read

  • Snapchat Plus Planet Order 2023 Explained
    Snapchat Plus Planet Order 2023 Explained
  • How to Track a Phone Number on Google Maps
    How to Track a Phone Number on Google Maps
  • Why is Money Important in Our Lives?
    Why is Money Important in Our Lives?
  • The Future of Personal Computers: What to Expect in the Next Decade
    The Future of Personal Computers: What to Expect in the Next Decade
  • Top 20 programmable logic controller manufacturers
    Top 20 programmable logic controller manufacturers
  • Difference Between Three-Phase and Single-Phase Power
    Difference Between Three-Phase and Single-Phase Power
  • Apptronik says its humanoid robot will ‘redefine the future of work’
    Apptronik says its humanoid robot will ‘redefine the future of work’
  • Top 20 electric vehicle charging station companies
    Top 20 electric vehicle charging station companies
  • Starship Technologies now offering autonomous robot delivery on 50 US college campuses
    Starship Technologies now offering autonomous robot delivery on 50 US college campuses
  • Robotics market will be worth $218 billion by 2030, forecasts GlobalData
    Robotics market will be worth $218 billion by 2030, forecasts GlobalData

Overused words

ai applications automated automation automotive autonomous business companies company control customers data design development digital electric global industrial industry logistics machine manufacturing market mobile operations platform process production robot robotic robotics robots safety software solution solutions system systems technologies technology time vehicle vehicles warehouse work

Secondary Sidebar

Latest news

  • VanceAI Art Generator Guide: Create Visuals in Few Steps
  • VanceAI Photo Editor Can Ease Your Workflow
  • Mastering Time Tracking: How to Properly Utilize Simple Time Clock Software
  • What are the key benefits of website visitor detection tools?
  • What Does a Switch Do in a Network?
  • The Best Rust AK-47 Skins in 2023
  • Palletizing Systems and Robots
  • Exchange vs OTC: Deciphering the Best Fit for Large Volume Crypto Trades
  • Legal Remedies: Tips for Affected Employees in Overtime Pay Violations
  • Zendesk Data Migration Made Simple: Explore Options Available

Footer

We are…

Robotics and Automation News was established in May, 2015, and is now one of the most widely-read websites in its category.

Please consider supporting us by becoming a paying subscriber, or through advertising and sponsorships, or by purchasing products and services through our shop – or a combination of all of the above.

Thank you.

Independent

Archivists

November 2022
M T W T F S S
 123456
78910111213
14151617181920
21222324252627
282930  
« Oct   Dec »

Complex

Old-skool

This website and its associated magazine, and weekly newsletter, are all produced by a small team of experienced journalists and media professionals.

If you have any suggestions or comments, feel free to contact us at any of the email addresses on our contact page.

We’d be happy to hear from you, and will always reply as soon as possible.

Future-facing

Free, fair and legal

We support the principles of net neutrality and equal opportunities.

Member of The Internet Defense League

Copyright © 2023 · News Pro on Genesis Framework · WordPress · Log in

We use cookies on our website to give you the most relevant experience by remembering your preferences and repeat visits. By clicking “Accept”, you consent to the use of ALL the cookies.
Do not sell my personal information.
Cookie SettingsAccept
Manage consent

Privacy Overview

This website uses cookies to improve your experience while you navigate through the website. Out of these, the cookies that are categorized as necessary are stored on your browser as they are essential for the working of basic functionalities of the website. We also use third-party cookies that help us analyze and understand how you use this website. These cookies will be stored in your browser only with your consent. You also have the option to opt-out of these cookies. But opting out of some of these cookies may affect your browsing experience.
Necessary
Always Enabled
Necessary cookies are absolutely essential for the website to function properly. These cookies ensure basic functionalities and security features of the website, anonymously.
CookieDurationDescription
cookielawinfo-checkbox-analytics11 monthsThis cookie is set by GDPR Cookie Consent plugin. The cookie is used to store the user consent for the cookies in the category "Analytics".
cookielawinfo-checkbox-functional11 monthsThe cookie is set by GDPR cookie consent to record the user consent for the cookies in the category "Functional".
cookielawinfo-checkbox-necessary11 monthsThis cookie is set by GDPR Cookie Consent plugin. The cookies is used to store the user consent for the cookies in the category "Necessary".
cookielawinfo-checkbox-others11 monthsThis cookie is set by GDPR Cookie Consent plugin. The cookie is used to store the user consent for the cookies in the category "Other.
cookielawinfo-checkbox-performance11 monthsThis cookie is set by GDPR Cookie Consent plugin. The cookie is used to store the user consent for the cookies in the category "Performance".
viewed_cookie_policy11 monthsThe cookie is set by the GDPR Cookie Consent plugin and is used to store whether or not user has consented to the use of cookies. It does not store any personal data.
Functional
Functional cookies help to perform certain functionalities like sharing the content of the website on social media platforms, collect feedbacks, and other third-party features.
Performance
Performance cookies are used to understand and analyze the key performance indexes of the website which helps in delivering a better user experience for the visitors.
Analytics
Analytical cookies are used to understand how visitors interact with the website. These cookies help provide information on metrics the number of visitors, bounce rate, traffic source, etc.
Advertisement
Advertisement cookies are used to provide visitors with relevant ads and marketing campaigns. These cookies track visitors across websites and collect information to provide customized ads.
Others
Other uncategorized cookies are those that are being analyzed and have not been classified into a category as yet.
SAVE & ACCEPT