AUTO IBN² - Efficient assembly and innovative commissioning processes in the production of modern vehicles

Problem definition and objectives

In the ERDF-supported project, new human-robot-capable assembly processes for the automotive industry are being developed in cooperation with various partners.

ZeMA is a partner in the scientific community “Assembly, Handling and Industrial Robotics”. In addition, there are cooperation agreements with leading robot manufacturers such as Kuka, ABB and Bosch.

In order to avoid a medium-term relocation of final vehicle assembly due to cost pressure from the high-wage location of Saarland or Germany to countries with low wage levels, the economic efficiency of final vehicle assembly must be increased. One way of doing this is to increase the efficiency of the assembly and testing processes in the automotive industry.

The aim is to give new impetus to efficient production processes by developing innovative commissioning and assembly processes for motor vehicles. This offers the possibility to present or implement prototypical processes on the existing demonstrator depending on the application. Thereby the challenges and potentials of the construction of modern vehicles are addressed. At the same time, the project strengthens the competitiveness of German and local manufacturers of plant and equipment. The steady increase in electronic components and the high number of mechatronic functions in vehicles tends to lead to increasing costs in final vehicle assembly and commissioning. In principle, the aim is not only to avoid workloads but also to use the mechatronic capabilities of vehicles for innovative and efficient process solutions. This should make work and process sequences more efficient. Furthermore, the structure of the assembly process is to be changed for optimisation.


The AutoIBN2 project is a cross-disciplinary project that combines organisational and production-related issues. The main research focus of the project is the joint development of production strategies and technologies for cyber-physical production plants and efficient assembly processes. Using smart equipment and intelligent methods, this will be demonstrated using the example of final vehicle assembly and its associated areas. This will be based on the latest developments in vehicle technology, modern approaches in the field of information technology and also robot technology. This will result in fundamentally new research approaches to improve quality and ensure efficient vehicle production at a high-wage location.

The project contains 5 work packages:

– Inline measurement: In-line measurement of the geometric vehicle axis using the developed wheel adaptation system and adjustment of the driver assistance systems in the assembly line

– Worker assistance systems for flow assembly: Innovative human-robot concepts for the automation of production and testing processes in the flow assembly line

– Virtual plant engineering: methods and tools for the development, design and virtual commissioning of robust production plants

– Energy efficiency for the cyberphysical production network: development of methods and applications for the energy-efficient operation of production plants in different operating states

– Model and test factory environment

Current project status and results

The project was launched in mid-2015 and will run for at least 3.5 years. The work plan is structured in such a way that the contents of the work packages start in parallel and reach a common project status in the form of a development environment at the end of the project.

Recycling concept

The development environment created will be used to validate processes and enable continuation projects with industry and research services. In addition, the demonstrator and the research results will be used to apply for and conduct further research projects. Furthermore, the equipment will be used for teaching and further education measures.


Duration: 07.06.2015-31.12.2018
Supported by: EU EFRE

Contact: ZeMA