Case Study

Robotic Seat Assembly Line for Electric Vehicle Manufacturer

Project Snapshot

The Chief Engineer for an automation company was challenged by an electric vehicle manufacturer with a new project to automate the assembly of an automotive seat. They were awarded the project weeks before Thanksgiving with an extremely compressed delivery schedule. The client needed to engage a reliable partner to develop the design of a robotic work cell assembly system, so that it could be released to manufacturing 8 weeks after the project kick-off meeting. Ultimately a main layout, full assembly drawings, bill of materials and detailed part drawings were needed for the deliverables package.

Project Size



18 Weeks

Project Team

9 Engineers


Machinery Manufacturing

Project Challenges

Electric vehicle manufacturer was conducting concurrent product design while Sterling was designing the robotic work cell automation design.
Project kick off started weeks before Thanksgiving, collaborative design spanned Thanksgiving/Christmas/New Year Holiday and deliverables needed to begin to be released to manufacturing 8 weeks after the project kick off.
Due to the new seat assembly / robotic automation technology, concurrent design was needed to accelerate the R&D effort to meet the tight deadlines.

Sterling’s Solution

Our client specified their proprietary assembly line that would index the product. The workflow layout was verbally communicated, and Sterling’s team broke down each module and assigned it to engineering teams. The automotive company specified which robot brand and Sterling specified the model needed. It would be up to Sterling to add details and dimensions to make this an efficient and precise layout.
Sterling’s work tasks were broken down into:

  • Robot size specification
  • Component delivery systems
  • Machine locations
  • Robot end effectors
  • Work holding
Sterling assigned the lead design engineers and detail designers. The detail drawing work utilized an off-shift team to compress the schedule. The work was allocated in a manner that leveraged all resources and allowed for the teams to work concurrently around the clock.
The project was delivered on time and within the budget allowing the client to save the order. The Solidworks 3D-CAD models, detailed parts drawings, Timing Charts, and installation assembly drawings enabled them to secure the revenue and keep their client. Sterling works with many automation companies and protects their client’s customers.

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