#China #Chery Automobile #Dalian #ForwardX Robotics #AMR Technology

Introduction to Brownfield Automation

Most automotive factories are designed with production efficiency in mind rather than automation. This makes transitioning existing facilities to new automated systems a monumental challenge, particularly in brownfield environments where operations must not be interrupted. One remarkable example of overcoming these challenges is showcased by ForwardX Robotics, which successfully deployed 484 Automated Mobile Robots (AMRs) at Chery Automobile's manufacturing facility in Dalian.

The Scope of the Deployment

Since the start of the deployment over a year ago, ForwardX's AMR systems continue to integrate within the existing structures of the Dalian factory without any downtime in production. This achievement highlights one of the largest brownfield automation projects in the automotive sector, consisting of extensive implementations of AMRs across various workshop areas. The Dalian facility is known for its high output, producing approximately 1,000 vehicles daily, necessitating continuous operational efficiency.

Key Statistics of the Deployment:

• - 484 AMRs deployed across the facility
• - Support for 127 material categories automated
• - Integration within Bodyshop and Final Assembly workshops
• - Continuous production maintained throughout deployment efforts

Navigating Existing Challenges

Brownfield automation is particularly complex due to the existing factory's limited space, mixed traffic (with workers and forklifts), outdated IT infrastructure, and the varying demands of production. Retrofitting an operational factory presents a unique set of obstacles. While pilot programs may demonstrate success, scaling to hundreds of robots in real-time manufacturing environments introduces new challenges.

ForwardX's approach to these challenges involves a combination of vision-based autonomy, fleet orchestration, and phased implementation, allowing for a seamless integration with the existing workflows. The AMRs work alongside human workers, conveyor systems, and other material-handling equipment, minimizing the need for major changes to the facility structure.

Operational Integration and Strategy

To maintain production stability during the transition, ForwardX strategically applied a phased rollout combined with continuous optimization. In the Bodyshop, 204 AMRs quality-control and deliver materials for 32 categories, covering over 80% of the material demand. In contrast, the final assembly area benefits from 280 AMRs managing 95 material categories, supporting nearly 90% of assembly-line requirements.

Nicolas Chee, CEO and Founder of ForwardX Robotics, emphasizes that while robotics play a vital role in this transformation, the success of brownfield automation hinges significantly on the integration of systems and understanding the intricacies of factory operations. His insights reflect a paradigm shift, indicating a growing trend among Original Equipment Manufacturers (OEMs) and Tier 1 suppliers towards upgrading their existing facilities rather than pursuing new constructions.

Conclusion

The journey of automating Chery’s Dalian facility exemplifies the future of automotive logistics. While greenfield projects prove that robots can function effectively in isolated environments, brownfield initiatives like this one demonstrate the potential for automation to flourish in real-world manufacturing settings. As technology continues to evolve, we can expect similar transformations in existing factories to become common practice.

Looking Ahead

ForwardX will be showcasing their innovations at Automate 2026, encouraging industry players to explore the future of automotive logistics. Those interested in detailed insights on this project can download the Chery Dalian Brownfield Automation White Paper from the ForwardX website.

In an era where efficiency and adaptability are vital, the Chery Dalian project stands as a beacon of advancement in the complex intersection of production and automation.