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FORD OTOSAN
Body & Assembly Shops
Equipment Information Document
Disclaimer
This document is confidential and intended solely for the use of the
individual or entity to whom it is addressed. If you are not the intended
recipient you are hereby notified that any forwarding, copying or use of the
information is prohibited. If you received this document in error, please notify
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sender. Please then destroy/delete this document (and the email, if received
by email) and any copies of it without retaining a copy. Any comments or
statements made herein do not necessarily reflect those of Ford Otomotiv
San A.Ş., its subsidiaries and affiliates. If received in digital form, it is the
responsibility of the recipient to ensure that it is virus free and no
responsibility is accepted by Ford Otomotiv San A.Ş. or its subsidiaries or
affiliates either jointly or severally, for any loss or damage arising in any way
from its use.
Sale Package
The package to be sold is composed of:
• 3 pairs of symmetrical full-automated vehicle bodyside lines
• 2 different full-automated complete vehicle body framing lines,
• 1 semi-automated vehicle underbody line,
• Manual weld guns,
• Several material handling equipments and conveyors (Body &
Assembly)
• Miscellaneous/unique equipments.
Contents
1. Body Shop
1.1. Framing 1
1.2. Framing 2
1.3. Bodyside 1 (Left)
1.4. Bodyside 1 (Right)
1.5. Bodyside 2 (Left)
1.6. Bodyside 2 (Right)
1.7. Bodyside 3 (Left)
1.8. Bodyside 3 (Right)
1.9. Underbody
1.10. Manual Weld Guns
1.11. Miscellaneous/Unique equipments
2. Assembly Shop
2.1. Skillet Conveyors
2.2. EMS Carriers (for windscreen assembly)
2.3. Body Overhead Conveyor Systems
2.4. Engine Assembly And Mounting Dollies
2.5. Engine Assembly Dollies
2.6. Fluid Filling Stations
2.7. End Of Line Lift and Conveyor
1. BODY SHOP
1.1. Framing 1
Lay-Out
Specifications
Number of stations 17
Number of robots 33
Line capacity (actual) 31 veh/hour
Conveyor type Independent power roller bed conveyor system
Process summary • Spot welding of underbody, right&left bodysides and roof structure
(geometry and respot)
• Automated underbody floor drilling operations
• Additional manual MAG welding operations in closed cabinet.
1.1. Framing 1
Visuals
1.1. Framing 1
Major Equipments
Item Model Count
Comau Robot See next page for details 33
Robotic Spot Weld Gun Sciaky / ARO 40
Robotic Sealer Unit SCA 3
Tool Changer Walther-Präzision 32
Electrode Changing Machine (Elektrodmak) - 11
Electrical tip dresseer AEG 32
Turn Table - 1
MAG Welding Machine - 7
1.1. Framing 1
Robot Details
1.2. Framing 2
Lay-Out
Specifications
Number of stations 7
Number of robots 11
Line capacity (actual) 19 veh/hour
Conveyor type Independent power roller bed conveyor system
Process summary Spot welding of underbody, right&left bodysides and roof structure
(geometry and respot)
1.2. Framing 2
Visuals
1.2. Framing 2
Major Equipments
Item Model Count
ABB Robot See next page for details 10
Comau Robot See next page for details 2
Robotic Spot Weld Gun Nimak 12
Tool Changer Walther-Präzision 22
Electrical tip dresseer AEG 15
Lift Turn Table - 1
MAG Welding Machine - 7
1.2. Framing 2
Robot Details
1.3. Bodyside 1 (left)
Lay-Out
Specifications
Number of stations 6
Number of robots 11
Line capacity (actual) 30 parts/hour
Conveyor type Lift shuttle in linked lines
Process summary Spot welding of left bodyside inner and outer panels (geometry and
respot)
Visuals
1.3. Bodyside 1 (left)
Major Equipments
1.3. Bodyside 1 (left)
Item Model Count
Comau Robot See next page for details 11
Robotic Spot Weld Gun Sciaky 12
Robotic Sealer Unit SCA 1
Tool Changer Walther-Präzision 4
Electrode Changing Machine (Elektrodmak) - 6
Electrical tip dresseer AEG 9
Robot Details
1.3. Bodyside 1 (left)
Sealer Robot Details
1.4. Bodyside 1 (right)
Lay-Out
Specifications
Number of stations 6
Number of robots 11
Line capacity (actual) 30 parts/hour
Conveyor type Lift shuttle in linked lines
Process summary Spot welding of right bodyside inner and outer panels (geometry and
respot)
Visuals
1.4. Bodyside 1 (right)
Major Equipments
Item Model Count
Comau Robot See next page for details 11
Robotic Spot Weld Gun Sciaky 12
Robotic Sealer Unit SCA 1
Tool Changer Walther-Präzision 4
Electrode Changing Machine (Elektrodmak) - 7
Electrical tip dresseer AEG 10
1.4. Bodyside 1 (right)
Robot Details
Sealer Robot Details
1.4. Bodyside 1 (right)
1.5. Bodyside 2 (left)
Lay-Out
Specifications
Number of stations 4
Number of robots 6
Line capacity (actual) 13 parts/hour
Conveyor type Lift shuttle in linked lines
Process summary Spot welding of left bodyside inner and outer panels (geometry and
respot)
Visuals
1.5. Bodyside 2 (left)
Major Equipments
Item Model Count
ABB Robot See next page for details 6
Robotic Spot Weld Gun Nimak / ARO 8
Tool Changer Walther-Präzision 8
Electrical tip dresseer AEG 8
Lift shuttle - 1
Robotic Sealer Unit SCA 1
1.5. Bodyside 2 (left)
Robot Details
1.5. Bodyside 2 (left)
1.6. Bodyside 2 (right)
Lay-Out
Specifications
Number of stations 4
Number of robots 5
Line capacity (actual) 13 veh/hour
Conveyor type Lift shuttle in linked lines
Process summary Spot welding of right bodyside inner and outer panels (geometry and
respot)
Visuals
1.6. Bodyside 2 (right)
Major Equipments
Item Model Count
ABB Robot See next page for details 6
Robotic Spot Weld Gun Nimak / ARO 8
Tool Changer Walther-Präzision 8
Electrical tip dresseer AEG 8
Lift shuttle - 1
Robotic Sealer Unit SCA 1
1.6. Bodyside 2 (right)
Robot Details
1.6. Bodyside 2 (right)
1.7. Bodyside 3 (left)
Lay-Out
Specifications
Number of stations 7
Number of robots 17
Line capacity (actual) 26 parts/hour
Conveyor type Lift shuttle in linked lines
Process summary Spot welding of left bodyside inner and outer panels (geometry and
respot)
Visuals
1.7. Bodyside 3 (left)
Major Equipments
Item Model Count
Kuka Robot See next page for details 17
Robotic Spot Weld Gun Nimak / ARO 18
Tool Changer Walther-Präzision 12
Electrical tip dresseer AEG 16
Electrode Changing Machine (Elektrodmak) - 14
Lift shuttle - 1
Robotic Sealer Unit SCA 4
Robotic Gripper Unit - 1
1.7. Bodyside 3 (left)
Robot Details
1.7. Bodyside 3 (left)
Sealer Robot Details
1.8. Bodyside 3 (right)
Lay-Out
Specifications
Number of stations 7
Number of robots 18
Line capacity (actual) 26 veh/hour
Conveyor type Lift shuttle in linked lines
Process summary Spot welding of right bodyside inner and outer panels (geometry and
respot)
Visuals
1.8. Bodyside 3 (right)
Major Equipments
Item Model Count
Kuka Robot See next page for details 18
Robotic Spot Weld Gun Nimak / ARO 18
Tool Changer Walther-Präzision 12
Electrical tip dresseer AEG 16
Electrode Changing Machine (Elektrodmak) - 14
Lift shuttle - 1
Robotic Sealer Unit SCA 4
Robotic Gripper Unit - 1
1.8. Bodyside 3 (right)
Robot Details
Sealer Robot Details
1.8. Bodyside 3 (right)
1.9. Underbody
Lay-Out
Specifications
Number of stations 6
Number of robots 1
Line capacity (actual) 23 parts/hour
Conveyor type Semi-automatic lift shuttle in linked lines + chain conveyors
Process summary Spot welding of underbody frame and floor pan
Visuals
1.9. Underbody
Visuals
1.10. Manual Weld Guns
Item Count
ARO 191
PW 181
Nimak 7
Visuals
1.11. Miscellaneous/Unique equipments
Specifications
Laser Cutting Booth (with 1 robot & source) OEM Robot: KUKA, LASER: Trumph, Cutting Head: Precitec Age: 2008 Booth Dimensions: 7,0 m x 5,0 m x 4,2 m
*One of the robots is not included into the sale package.
Visuals
1.11. Miscellaneous/Unique equipments
Specifications
Automatic Stud Weld Station (2 robots with t-stud units & turn table) OEM Manipulators: ABB IRB 6400/2.4-150, ABB IRB 6400/2.8-120 T-Stud Units: Tucker Age: 2000
T-Stud Units Manipulator&Controller Automatic Stud Station
Visuals
1.11. Miscellaneous/Unique equipments
Specifications
Pedestal Weld Machines (6 items) OEM Machine Type: Coşkunöz (Turkey) Age: 2000
2. ASSEMBLY SHOP
2.1. Skillet Conveyors
Visuals
Specifications
Number of items 52
Dimensions 6000 mm x 2800 mm x 450 mm
Notifications • Periodically controlled.
• Currently in use
2.2. EMS Carriers (for windscreen assembly)
Specifications
Number of items 2
OEM Daifuku (Japan)
Notifications • Electirified monorail system with vacuum generators
• Automatic elevation and manual windscreen assembly
Visuals
2.3. Body Overhead Conveyor Systems
Specifications
Number of items 29
OEM Daifuku (Japan)
Notifications • Vertical adjusting conveyor
• Maximum payload capacity: 1291 kg (work capacity)
Visuals
2.4. Engine Mounting Dollies
Visuals
Specifications
Number of items 6
OEM Daifuku (Japan)
Notifications • Payload capacity (incl. Tooling plate): 450 kg
• Superstructure: Hydraulic scissors lift with tooling fixture
2.5. Engine Assembly Dollies
Visuals
Specifications
Number of items 22
OEM Daifuku (Japan)
Notifications • Payload capacity (incl. Tooling plate): 350 kg
• Track length: 19,635 m
• Plate pitch: 800 mm – Work pitch: 2400 mm
2.6. Fluid Filling Stations
Visuals
Specifications
Number of items 4
OEM Dürr – Schenck (Germany)
Notifications • Windscreen washer water, coolant fluids, air conditioning gases
and brake fluid filling combined
2.7. End Of Line Lift and Conveyor
Visuals
Specifications
Number of items 1
OEM Daifuku (Japan)
Notifications • Vertical lift
• 2(600) x 91400 mm double slat type end of line chain conveyor.
• Pitch: 6000 mm
Contacts
Sale, Operation and Logistics Issues
Ayhan Kalkavan – Managing Director, Global Industry
Sedat Demir – Sales&Marketing Director, Global Industry
Kemal Karakaş – Operations&Logistics Director, Global Industry
Technical Issues and Package Content Details
For Body Shop Content,
Gökan Acar – Maintenance Engineer, Ford Otosan
For Assembly Shop Content,
Murat Doğan Ercan – Automation&Projects Engineer, Ford Otosan