CASE STUDY

Precision and efficiency in the automotive industry

Smart Automation designed and implemented a modular production line for BRUSS. The advanced automation system, based on a range of Siemens solutions, maintains consistent performance regardless of the variant of the component being produced.

BRUSS is a leading global supplier of automotive products in the fields of sealing technology and powertrain control. In manufacturing its solutions, it uses, among others, plastic injection molding processes.The need to increase production capacity, alongside growing requirements for higher manufacturing precision, led to the construction of a new modular production line at the company’s Polish plant.

"In addition to boosting production, our goal was also to improve the quality parameters of the final product. This was not possible using the existing production line at our Mrągowo facility, whose performance was below our needs at the time,"
recalls Damian Rowiński, Launch & Process Manager at BRUSS Sp. z o.o.

It was therefore decided to build and commission a second line, designed to enable precise component production while significantly increasing manufacturing efficiency. The task of designing and delivering a modular production line for the automated assembly, marking, and quality inspection of covers for three- and four-cylinder gasoline engines was entrusted to Smart Automation, a company specializing in the automation and robotization of industrial processes.

"Already at the design stage, we carried out a detailed verification of technical solutions, introducing numerous improvements compared to the older line. In the new installation, we opted for a comprehensive approach and full integration of Siemens technologies, ensuring consistency and maximum efficiency of the entire system,"
emphasizes Radosław Szymański, Project Manager at Smart Automation.

The implementation began in June 2023 with the concept development phase, during which the layout of stations and modules, the allocation of injection molding machines, and operator workstations were designed. In the next stage, a 3D model of the entire line was created, including a visualization of technological processes.The documentation phase—completed with the initiation of the project order—included a full 3D model, electrical and pneumatic schematics, and a bill of materials. The initial pre-commissioning of the line was carried out at Smart Automation’s facility, serving as a key step in testing before full deployment. Subsequently, the complete line was tested on-site at BRUSS, culminating in formal acceptance of the application in December 2024.

The production line built by Smart Automation enables precise component manufacturing and significantly increases production efficiency

Production process from start to finish

The line consists of fourteen stations, with components transported on pallets in a closed-loop system.

Engine cover assembly takes place on a modular production line consisting of 14 stations. Components are transported on pallets in a closed-loop system. The process begins with a manipulator picking a fresh part from the injection mold, weighing it for mass control, and placing it on a transfer pallet. The part then passes through a thermal stabilization system for controlled cooling and is marked with a unique DMC code. The system continuously monitors line performance. If the buffer is full, parts are stored, while others proceed to further stages.

"In the next step, two stations equipped with manipulator systems perform insert assembly using induction heating technology. The process then moves to a manual-automatic station, where the operator pre-installs flow control inserts and positions the part in a laser welding unit. After the cycle, the component is returned to the pallet transport system,"
explains Radosław Kokornacki, Head of Automation at Smart Automation.

In the next stage, a vision system verifies the correctness of insert assembly with an accuracy of 0.02 mm, checking the presence and flow of openings as well as any casting defects, performing screening measurements according to defined parameters. The operator then inserts self-tapping screws into the holes and installs pressure control valves. Finally, the screws are automatically tightened and the flatness of the cover is measured with an accuracy of 0.01 mm. After these steps, the product is almost complete—only the installation of seals remains. However, this is not yet the end of the production process.

In the next stage, another station automatically cleans both the upper and lower surfaces of the cover. Afterward, at the following station, operators install seals using molds. Finally, seven pressure tests are carried out to verify tightness, flow, permeability, and valve operation. A dedicated station then checks the position of pressure valves, the presence of screws and inserts, and applies a safety label. The final station releases finished parts to the operator, stores defective components, handles buffers, parts requiring rework, reference samples, and reloads pallets.

At full capacity, the line produces two different types of covers simultaneously, ensuring a continuous workflow, with a cycle time of 33.5 seconds

Damian Rowiński , Launch & Process Manager, BRUSS

SMART line

The quality of final products is crucial for BRUSS, which is why it was essential for Smart Automation to implement a comprehensive production parameter control system.

"We ensured full traceability of every manufactured part. Collected data—such as cycle times of individual stations, entry and exit timestamps, and test results—enable precise calculation and monitoring of the OEE indicator. Quality verification includes pressure testing, geometry inspection using an advanced vision system, as well as checks of workmanship and the presence of elements such as screws, valves, and warning labels,"
says Radosław Kokornacki.

The line is equipped with a proprietary management, reporting, and process data monitoring system developed by Smart Automation. This solution provides BRUSS employees with secure remote access to real-time production status from anywhere. Users can analyze overall performance, detailed station data, process history with parameters, and monitor quality and efficiency indicators on an hourly, shift, and daily basis.

The line features a proprietary management, reporting, and process data monitoring system developed by Smart Automation.

"The injection molding machine used by BRUSS produces plastic covers using injection molding technology. The line we built automatically controls their quality and integrates components such as screws and seals. As a result, switching product types involves minimal downtime, ensuring production flexibility without significant changes to other modules,"
explains Radosław Szymański.

The changeover process for a different product range is highly automated. Manual replacement of sealing tooling is synchronized with the line’s material feed timing, effectively eliminating downtime for this operation.

The end customer and the machine manufacturer chose Siemens solutions. The hardware components and software we provide have met the demanding goals set by Smart Automation and BRUSS. This demonstrates the high functionality, versatility, and reliability of our complementary solutions, which literally ‘drive’ industrial production lines in our country

Sławomir Kalita, Sales Manager, Siemens

The production line operates based on a wide range of Siemens solutions—from industrial PCs and controllers, through drive systems, power supply units, and I/O stations, to RFID readers and HMI panels

Technology for top quality and production efficiency

In the project, the contracting authority, BRUSS, was responsible for precisely defining the functional assumptions and quality requirements for the automated production line. Smart Automation, acting as the system integrator and contractor, handled the entire scope of work: from design and configuration to software development, assembly, testing, and commissioning of the line, ensuring production flexibility and high efficiency.

“Siemens supported the initiative as a supplier of key automation components, providing technologies that drive the production line and enable comprehensive management and control of the engine cover assembly process on the automated line developed by Smart Automation,”
– explains Sławomir Kalita.

For the construction of the production line, SIMATIC S7‑1500TF controllers with extended technological functionality were used, enabling the implementation of advanced motion control algorithms and meeting the highest safety standards thanks to the Safety Integrated feature. The controllers were integrated with SINAMICS S210 and V90 servo drives, ensuring precise axis control.The modular architecture of the line, based on distributed ET200AL and ET200SP I/O systems, enabled flexible configuration and quick changeovers. The system was complemented by RFID readers for component identification, industrial network switches, operator panels from the latest SIMATIC HMI Unified series, and a comprehensive range of switching devices ensuring reliable power distribution.

The use of Siemens technology provided us with a unified configuration, diagnostics, and operation without the need to switch between different software environments

Radosław Szymański, Smart Automation

Standing from left: R. Kokornacki, S. Kalita, R. Szymański, D. Rowiński

“The key element is the centralized management of the entire process within the TIA Portal environment, which integrates configuration, diagnostics, and simulation into a single tool. During the project, Smart Automation leveraged many capabilities of the TIA Portal platform, including built-in drive blocks, integrated safety mechanisms, a Multiuser mode enabling parallel project editing, and the S7‑PLCSIM Advanced tool for simulation and testing of control logic prior to physical commissioning,”
recalls Sławomir Kalita from Siemens.

The project’s pace was exceptionally dynamic, reflected in rapid decision-making and continuous progress despite technical challenges encountered at every stage.

“Our goal was to build a production line that would ensure high repeatability, precision, and full traceability of parts at every stage of production, while also enabling increased process efficiency and comprehensive production management. We were able to fully achieve this goal thanks in part to Siemens’ support and the use of this manufacturer’s reliable components and software,”
emphasizes Radosław Kokornacki.

“The production line is characterized by high flexibility. We continuously introduce parameter adjustments and process improvements. In the near future, we plan further upgrades and expansion of the installation,”
– summarizes Damian Rowiński, Launch & Process Manager at BRUSS sp. z o.o.