ABB robots form part of islands of automation to build body shells at Jaguar Cars

Purpose – Describes how Jaguar Cars in the UK is using robots to manufacture aluminium car bodies for its new XK sports car that is being built in the company's plant in Castle Bromwich, UK. Design/methodology/approach – Describes the major production line techniques that are used in the manufacture of the body‐in‐white structure. These include self‐piercing rivets (SPRs), self‐tapping screws, MIG welding and adhesives. Findings – The use of SPRs and self‐tapping screws are proving essential in the joining of aluminium components manufactured as extrusions, castings and pressings. Research limitations/implications – The introduction of SPRs and self‐tapping screws, adhesive bonding and MIG welding of cosmetic aluminium skin panels is the result of considerable research work on the part of Jaguar engineers and the company's suppliers, as well as Warwick University. Three of these techniques require the services of robots with their integrated controls. This work is likely to continue in order to reduce cycle times and improve overall product performance, both to the benefit of manufacturer and end‐user – the customer. This paper provides a unique insight into the development of a facility with islands of automation to produce aluminium body shells. Practical implications – It is likely that arising out of development work into new techniques, processes and standards that will be used throughout the Ford organization, including other companies that form the Premier Automotive Group. Aston Martin, Land Rover and Volvo could all benefit from the technologies developed at Jaguar Cars. Originality/value – This is the first time Jaguar Cars has used ABB robots in significant numbers to apply SPRs and self‐tapping screws to join aluminium components. ABB robots are also used for body shell inspection and MIG welding aluminum skin panels.