Assembly Lines
Virtual Reality Lab Helps Stellantis Engineers Improve Assembly Lines
Stellantis engineers are using virtual reality technology to enable operators to assemble vehicles smarter, faster and safer.
Photo courtesy Stellantis
AUBURN HILLS, MI—Engineers at Stellantis are using virtual reality tools to simulate assembly line workstations before actual production begins. They are using the technology to analyze hundreds of postures to find optimal configurations, tailored for a variety of physical requirements.
The state-of-the-art VR lab allows engineers to optimize plant layouts and refine installation procedures. The goal is to enable operators to assemble vehicles smarter, faster and safer.
The facility is strategically located near the Chrysler Technology Center’s pilot production plant, where early builds of new vehicles are tested and validated. It is equipped with cutting-edge tools such as motion capture, physics-based part simulations and digital twin integration that provide real-time visualization, data accuracy and immersive problem-solving.
“Manufacturing is at the heart of what we do, and advanced technologies like virtual reality allow us to continuously raise the bar,” says Tim Fallon, senior vice president of North America manufacturing at Stellantis. “By identifying issues before production starts, we’re making our facilities safer and better capable of delivering world-class quality to our customers.
“VR is essential for evaluating the postures and movements of hundreds of operators,” explains Fallon. “Deploying this data in a digital environment that mirrors real-life assembly conditions helps ergonomics teams fine-tune platform heights, set ‘golden zones’ for operator’s reach, and refine part-handling techniques for greater safety and efficiency.”
According to Fallon, the VR lab is the centerpiece of Stellantis’ digital engineering efforts, providing a full-scale, immersive platform to “proactively resolve manufacturing challenges and drive operational excellence.”
As a result of deploying VR, Stellantis has identified and resolved hundreds of potential issues on its assembly lines before production begins. For example, the technology was used to help determine the optimal vehicle height for making underbody electrical connections at the Sterling Heights and Warren Truck assembly plants.
Looking for quick answers on assembly and manufacturing topics? Try Ask ASM, our new smart AI search tool. Ask ASM
By simulating multiple line heights in a virtual environment, engineers ensured that operators would have the proper reach and access to perform these connections safely and efficiently, without ergonomic strain. “Conducting these sessions early in the design process allowed the team to establish accurate conveyor height requirements well before installation, supporting both worker safety and production readiness,” claims Fallon.
“As part of [our] global manufacturing initiative, [we are] scaling VR technology across regions to improve quality, reduce downtime and support [our] long-term vision for smarter, more sustainable production,” says Fallon.
Looking for a reprint of this article?
From high-res PDFs to custom plaques, order your copy today!
