How ForwardX Seamlessly Deployed 484 Autonomous Robots in an Active Auto Factory

The Challenge of Automation in Existing Factories

In today's rapidly evolving industrial landscape, the integration of automation in existing manufacturing facilities presents a daunting challenge. ForwardX Robotics has tackled this head-on with their groundbreaking deployment of 484 mobile autonomous robots (RMA) in Chery Automobile's Dalian factory. This initiative is not just a technological advancement; it represents a significant milestone in the transition toward automated processes without disrupting ongoing production.

Understanding the Automation Challenge

Many automotive plants, like Chery’s, were originally designed for mass production, not for automation. Unlike newer facilities that can be built with automation in mind from the ground up, existing factories must adapt their infrastructure and workflows to incorporate new technologies. This often means working around established machinery, staff duties, and production schedules, which makes automation a complex task.

Progress and Integration

More than a year into the implementation, ForwardX’s RMA system has continually expanded across the Chery facility, achieving remarkable success without halting production. The factory produces an impressive 1,000 vehicles per day, making production consistency a critical operational requirement. The integration of RMA began in production areas responsible for welding and final assembly, allowing the robots to handle extensive intralogistics processes including supply delivery, transporting parts, and returning empty containers.

Specifically, 204 RMA units are supplying 32 categories of components within the body shop, fulfilling over 80% of supply needs. Additionally, in the final assembly workshop, 280 RMA units are responsible for the transportation of 95 different part categories, meeting nearly 90% of assembly line supply requirements.

Navigating Unique Challenges

One of the most significant hurdles in automating existing facilities lies in the unique challenges they present. With limited space near the production line, a mix of human workers, forklifts, and existing robotic systems all operating at once, it is imperative to ensure that automation can coexist with traditional manufacturing practices. The transformation must occur seamlessly; any major disruptions could hinder operational efficiency and productivity.

To tackle these complexities, ForwardX has employed an array of strategies merging vision-based autonomy, fleet orchestration, and manufacturing integration. Their approach does not require major changes to the existing setups. Instead, the RMAs were interwoven into the workflow, collaborating with other workers and equipment to facilitate smooth operations.

The ForwardX Approach

According to Nicolas Chee, founder and CEO of ForwardX Robotics, the key to transforming a live factory while preserving production lies not solely in applying robotics but in achieving a deep understanding of production dynamics. The deployment is characterized by gradual implementation and ongoing optimization, allowing automation technologies to be introduced without destabilizing existing workflows.

As automotive manufacturers and Tier 1 suppliers continue to modernize, the drive to automate existing facilities becomes a pressing concern across the industry. Most future investments in automation are likely to take place in these established factories rather than new constructions.

ForwardX’s project in Chery Dalian serves as a groundbreaking example of how automation can be effectively executed in a real-world production environment. It demonstrates that while new facilities can showcase robotic capabilities, the true test lies in the deployment of these technologies within operational factories.

For those interested in exploring this topic further, ForwardX has released a white paper detailing the intricacies of automating existing facilities at Chery Dalian. To delve deeper into this case study and its outcomes, visit ForwardX's website.

Moreover, ForwardX will also showcase their innovative approaches at booth 1025 during Automate 2026, providing insights into the future of automotive logistics and automation.