#China #Automation #Chery Automobile #Dalian #ForwardX Robotics

The Challenge of Brownfield Automation

In the ever-evolving automotive landscape, automation is emerging as a game-changer. However, achieving this in existing factories, often termed 'brownfield' scenarios, presents unique challenges. ForwardX Robotics has set a remarkable precedent by deploying 484 Autonomous Mobile Robots (AMRs) in Chery Automobile's Dalian manufacturing facility without disrupting daily production.

Understanding Brownfield Automation

Automotive factories, accustomed to traditional production methods, are often not equipped to seamlessly integrate automation technologies. Unlike greenfield facilities, which are designed from the ground up for automation, brownfield environments must adapt existing systems to incorporate new technologies while maintaining operational efficiency. ForwardX's project not only aims to implement robust automation but does so in a setting that produces around 1,000 vehicles daily.

Throughout the year-long deployment, one of the standout achievements has been maintaining production continuity even as the AMRs were integrated into the workflow. This is crucial, as the Chery Dalian facility's ability to produce vehicles on schedule is directly tied to its operational requirements. The AMRs assist in various logistics processes—ensuring that material transportation alongside assembly tasks remains uninterrupted.

Key Numbers and Achievements

At the heart of ForwardX’s operation in Dalian is an impressive fleet of 484 AMRs, covering various production areas including the welding and assembly workshops. Specifically, the deployment supports the delivery of parts and materials critical for production:

• - In the Bodyshop: 204 AMRs manage 32 material categories, effectively supporting over 80% of the material demand.
• - In Final Assembly: 280 AMRs handle transportation for 95 material categories, ensuring nearly 90% of assembly-line requirements are satisfied.

This strategic utilization of AMRs has not only streamlined operations but has also provided significant insights into scalable automation within established factories.

Addressing the Core Challenges

Brownfield automation is fraught with challenges, including:
Limited space: Existing factories often have constrained areas for new equipment.
Mixed traffic: Factories operate with a combination of human workers, forklifts, and now, robots.
Legacy infrastructures: Many factories rely on old IT systems that may not be compatible with new automation solutions.
Adapting to fluctuating demands: Production requirements can vary day-to-day, necessitating a flexible response from the automated systems.

These complexities have necessitated a nuanced approach from ForwardX, combining vision-based autonomy with fleet orchestration and manufacturing integration strategies. Their phased deployment has allowed for adjustments based on real-time production requirements without significant disruptions.

Integrating Technology Seamlessly

The operational strategy employed underscores the importance of integrating robotics into existing manufacturing workflows. By doing so, ForwardX has demonstrated that it is possible to modernize legacy processes while preserving the essential output of existing operations. The success of this initiative showcases how far brownfield automation has come and sets a precedent for future transformations in the industry.

Nicolas Chee, Founder and CEO of ForwardX, emphasizes the significance of this achievement, stating, "The challenge is transforming an operating factory while protecting production. Brownfield automation requires much more than robotics. It requires integration, orchestration, and a deep understanding of manufacturing operations."

As the automotive industry progresses, the efforts of ForwardX and similar companies will become pivotal. The lessons learned from the Chery Dalian project pave the way for future investments in automation within established factories, illustrating not only that robots can be deployed but also that they can thrive in real-world manufacturing settings, proving their worth without compromising output.

To delve deeper into this innovative brownfield automation, interested parties can download an insightful white paper from ForwardX, exploring the extensive details behind this project. Additionally, participants are invited to experience these advancements firsthand at Automate 2026 in Booth #1025.

Conclusion

The success at Chery Dalian exemplifies the challenges and triumphs associated with brownfield automation. As manufacturers continue to seek efficient solutions to enhance productivity while mitigating downtime, the strategies and systems developed by ForwardX will likely serve as a blueprint for future transformations across the automotive sector.