Capabilities
BIW Turnkey Solutions
End-to-end advanced manufacturing engineering — bridging product design and production through process planning, digital simulation, and industrialization support.
From engineering concept to production launch.
Our Advanced Manufacturing Engineering (AME) team acts as the bridge between product design and the production floor — transforming engineering concepts into efficient, scalable, and high-quality manufacturing systems for the automotive BIW sector.
We integrate digital engineering tools, process simulation, and advanced manufacturing methodologies to minimise programme risk and enhance operational efficiency from the earliest stages of a new vehicle launch.
What We Bring
- Digital-first engineering approach
- Automotive BIW domain expertise
- End-to-end from feasibility to line commissioning
- Risk reduction through simulation before build
- Single-point accountability across the full programme
01 — What We Deliver
Our Four Service Pillars
Process Planning
Transforming programme requirements into structured, executable manufacturing plans.
- Planning & Feasibility Studies
- Process Flow Definition
- Cycle Time Analysis & Optimization
- Layout Development until Buy-off
- SFK Clamping Plan
- Equipment Definition & Specifications
- Manufacturing Cost Analysis
Digital Manufacturing & Simulation
Building and validating the production system in the digital twin before a single component is built.
- Robotic Simulation
- Digital Factory Planning
- Process Simulation & Validation
- Ergonomic & Safety Analysis
- Layout & Production Line Simulation
- SOP / MRS with Cycle Time Validation
- OLP (Offline Programming) Downloads
Production System Development
Designing the physical production system from line layout to production-ready equipment drawings.
- Production Line Planning & Layout Design
- Equipment & Tooling Definition
- Concept Development for Manufacturing Equipment
- 3D Design & Finalization of Manufacturing Equipment
- Release of Ordering List for Standard Equipment
- Assembly Line Development & Optimization
Industrialization & Launch Support
On-the-ground support from prototype builds through to full production ramp-up and commissioning.
- Detailing & Finalization of Manufacturing Equipment
- Foundation & Fence Plan
- Prototype & Pilot Build Support
- Production Ramp-up Management
- Safety Layout & Risk Assessment
- Assembly Documentation
- Line Commissioning Support
- Continuous Improvement Implementation
02 — Our Methodology
AME Delivery Workflow
01
Feasibility & Planning
Define scope, validate the manufacturing concept, and establish programme milestones before any engineering begins.
02
Digital Factory Setup
Build the virtual production environment — line layouts, station definitions, and equipment geometry in the digital twin.
03
Simulation & Validation
Robotic reachability, cycle time simulation, ergonomic checks — all risks resolved before physical build.
04
Production System Design
Full 3D equipment and tooling design with interference checks, BOM, and manufacturing drawings.
05
Prototype & Pilot Build
Support physical prototyping, pilot builds, and functional testing against production targets.
06
Launch & Commissioning
Ramp-up management, line commissioning support, and handover to production operations.
03 — Full-Spectrum Capability
End-to-end Engineering Solutions
Joining & Assembly Tooling
Development of manual and robotic spot welding fixtures engineered for repeatable positioning, weld accessibility, and high-volume production requirements.
Design of welding stations and fixtures for structural and closure assemblies with emphasis on rigidity, operator accessibility, and process consistency.
Engineering of hemming tools for doors, hoods, and tailgates, ensuring dimensional accuracy, surface quality, and reliable panel forming.
Fixture solutions for multi-material joining applications, integrating precise screw positioning, clamping strategies, and process monitoring requirements.
Manufacturing Support Equipment
Modular movable fencing and guarding solutions designed to provide operator safety while maintaining ease of maintenance and process accessibility.
Custom-designed platforms and walkways for safe access to robotic cells, fixtures, and process equipment.
Design and fabrication of equipment stands, support frames, and base structures engineered for durability and operational stability.
Production buffering systems and temporary storage solutions designed to improve line balancing and workflow efficiency.
Process-Specific Fixtures
Tooling solutions for component identification, traceability marking, and process verification throughout the manufacturing cycle.
Mechanically and pneumatically actuated systems for controlled component release and part transfer.
Precision tooling for sealant and adhesive application processes with controlled bead placement and repeatable quality.
Inspection fixtures designed for dimensional verification, GD&T evaluation, and assembly conformity checks.
Automated and manual part removal systems developed to ensure safe handling and smooth integration between manufacturing operations.
Material Handling & Automation Tooling
Robotic grippers designed for accurate part location, handling, and transfer of automotive panels and assemblies.
Custom lifting equipment for large panels, fixtures, and assemblies with a focus on safety and ergonomic operation.
Ergonomic handling solutions developed to reduce operator fatigue and improve productivity during assembly operations.
Engineered pallets and carrier systems for precise part transportation, process indexing, and automated line integration.
04 — Panel & Component Scope
Key Competencies for Automotive Panels for BIW Assembly Line
- Body Side Inner & Outer
- Front Door
- Rear Door
- Split Door
- Tailgate / Back Door
- Hood
- Fender
- Front Wheelhouse
- Rear Wheelhouse
- Underbody
- Roof
- Side Aperture
- Pillar (A, B & C Pillars)
- Reinforcement Panels
- Cross Members & Floor Panels
- Chassis & Structural
- Battery Tray & EV Structural
- BIW Sub-Assemblies & Closures
Build Your BIW Production System
Connect with our AME specialists to plan, simulate, and launch your next production line.
Get In Touch