XIAOLAN, China—Comau has designed and deployed a flexible body-in-white (BIW) manufacturing line for JMC Ford’s assembly plant here, which produces high-end pickup trucks. 

The project established a versatile production line capable of accommodating various models and configurations, including JMC Ford’s new pickup truck brand DaDao and Ford’s first pickup truck model introduced in the Chinese market, the Ranger. 

The scalable, fully automated line has improved welding accuracy and stability. The line also optimizes production processes and includes the adoption of advanced automation technologies to enhance production efficiency, reduce cycle times and increase output. By incorporating both welding and fastening tools within an integrated system, Comau was able to minimize the need for frequent tool changes. The line also leverages advanced vision inspection technology for better quality control.

Comau developed a flexible and removable fixture loading table that can be easily reconfigured for different assembly tasks and parts. This design reduces line changeover times, reduces tooling investments, optimizes workflow, and improves product quality. Moreover, the comprehensive manufacturing setup also features Comau’s OpenGate system, which ensures geometrical accuracy while granting inherent flexibility. On average, the system can switch to an new model in just 50 seconds.

“Our goal was to create a more efficient, reliable, and flexible production line for the rapidly expanding pickup truck market, and we have achieved impressive outcomes,” said Ma Jian, head of manufacturing engineering at JMC Ford.