Transforming Automation in Manufacturing: ForwardX's Success Story at Chery Dalian

The automotive industry is at a pivotal moment where automation is becoming not just an enhancement but a necessity. ForwardX Robotics, a leader in automation technology, has successfully deployed 484 Autonomous Mobile Robots (AMRs) in the Chery Automobile factory located in Dalian, China, proving that significant automation can be achieved in an existing facility without any production downtime.

The Challenge of Brownfield Automation

While many new factories are being designed from the ground up to incorporate automated systems, existing plants—often referred to as brownfield facilities—pose unique challenges. These facilities are accustomed to traditional manufacturing processes and layouts. Integrating automation into a space where it wasn’t initially intended requires careful planning and execution. In the case of the Chery Dalian plant, the goal was clear: implement a substantial robotics infrastructure without disrupting the production of approximately 1,000 vehicles per day.

ForwardX implemented a comprehensive strategy that focused on continuous adaptation and integration into the existing workflows. During the deployment phase, the AMRs were integrated into the operations without the need for extensive renovations or prolonged shutdowns. This was a crucial aspect because any interruption in production could lead to significant financial losses.

How It Works

In the Chery Dalian plant, the AMRs support various logistic processes, enhancing efficiency in tasks such as material delivery, transportation of assembly line carts, and returning empty containers. Within the body shop, 204 AMRs are responsible for supplying 32 categories of materials, successfully covering over 80% of the material needs. In the final assembly line, 280 AMRs manage the transport of 95 distinct material categories, thereby fulfilling nearly 90% of the material requirements needed for assembly.

The automation initiative intertwines with the existing workforce, conveyor belts, robotic installations, and other material transport systems. This integration is crucial as it allows for a smooth transition to automated processes without hindering the established operations.

Strategic Implementation

ForwardX's deployment strategy was strategic and gradual. The integration of AMRs was carried out in phases, allowing ongoing adjustments and optimizations. This approach ensured that production stability was continually preserved while introducing automation technologies.

As Nicolas Chee, the CEO of ForwardX Robotics, noted, “The challenge lies in reshaping an operational factory while securing production.” This highlights the complexity of transforming brownfield sites, where renovations must consider existing infrastructures that are already under pressure from production demands.

ForwardX’s methodology blends vision-based autonomy, fleet coordination, and manufacturing integration. This combination enables the operation of AMRs alongside human workers and conventional machinery. The unique challenges faced by existing factories, ranging from limited space on the production floor to mixed traffic conditions with personnel and forklifts, required a versatile and intelligent approach to implement automation.

The Future of Brownfield Automation

As Original Equipment Manufacturers (OEMs) and Tier-1 suppliers focus on modernizing their factories, the shift toward brownfield transformation is becoming increasingly significant. Rather than merely investing in new, greenfield projects, companies are recognizing the value in upgrading existing operations.

Brownfield projects, such as the one at Chery Dalian, provide a proof of concept that not only can robots function effectively but that automation technologies can be scalable within real-world manufacturing environments. As production needs evolve, so too must the factories that meet them.

In conclusion, ForwardX Robotics is leading the charge in demonstrating that automation can thrive in existing facilities without compromising operational outputs. This successful implementation at Chery Dalian serves as a roadmap for the industry, showcasing the potential of robotics to revolutionize the traditional manufacturing sector while ensuring production remains uninterrupted.

For those interested in exploring the full impact of this case study, ForwardX has made available a white paper detailing the automation of the Chery Dalian facility. Attendees can also meet ForwardX at Automate 2026 at booth number 1025, where the future of automotive logistics will be on display.