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Maserati’s Parallel Assembly Strategy

2 models, 1 line, unprecedented precision

​Maserati is one of the most prestigious race and sports car manufacturers in the world.  Representing more than just a symbol of elegance and style, Maserati has become a prestigious symbol of Italian technology and modernity.

In designing the production strategy for two of its most luxurious automobiles, the Quattroporte and the Ghibli, Maserati teamed with Comau Robotics to develop an innovative robotic solution based on articulated robots and advanced software applications that can fully automate complex bodyshop operations with extreme precision. What’s more, its advanced flexibility means the line can be programmed to automatically determine whether the piece is for the Quattroporte or Ghibli, and can produce one of the two models, or both, in a continuous flow, depending on production needs.

 
 

Customer Goals

  • Parallel production of multiple models in a continuous flow without interruptions
  • Total automation: from welding and subcomponent assembly to Tucker stud installation and roller hemming
  • In-sequence processing with simultaneous welding and assembly operations
  • Extreme precision and accuracy

Targeted Solutions

  • 82 Comau robots
  • Seamless integration between the sheet metal working and body assembly lines
  • Fully automated, multi-model, parallel production solution
  • Compete flexibility to produce one or both models on demand
  • Comprehensive tests and controls to guarantee Maserati quality standards

Results

  • Streamlined build times and full coordination between manual and automated processes
  • Simultaneous processing of parts and subgroups on models with different components and chassis lengths
  • Optimal 316-second cycle time for the sheet metal working phase
  • 4,785 welding spots for each model: 3,702 of which are performed during the sheet metal working phase with 2,677 of these performed automatically
  • Automated application of 190 rivets and 243 arc-welded studs for each model
  • 66 meters of semi-structural adhesive spread by robots (13 meters spread manually)
  • Production capacity of 50,000 luxury vehicles per year

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