Date initiated & completed: 2016

PROJECT DESCRIPTION

In 2016, SAR played a crucial role in restructuring the routing
of the BMW paint shop’s 7-meter-level body routing. This
project was carefully planned to minimize disruption to
production, avoiding the need for any shutdown periods during
installation.
By breaking down the project into distinct steps, we were able
to execute it incrementally over weekends. This ensured that
each phase of the restructuring could be completed weekend
by weekend, ultimately creating the successful implementation
of the new routing system without interrupting ongoing
production operations.
The project expanded over most of 2016 due to the weekend
approach.

TECHNOLOGIES

CONVEYOR TECHNOLOGY
SIEMENS SOFTWARE TIA AND S7
ROLLER BED
SHUTTLES
TURN TABLES
HOISTS
TILTING STATIONS

Date executed: December 2018

PROJECT DESCRIPTION

In December 2018, BMW initiated a standard maintenance
procedure to replace all copper EMS rails with Vahle rails as
the chosen conductive bus bar system. As SAR had not
previously performed in-house installations of Vahle rails, we
conducted comprehensive training sessions to ensure a
seamless and fully integrated implementation.
Following the training of personnel, we are pleased to say that
the project was a great success, with the system operating
smoothly and without any subsequent callbacks. The Vahle
rail, spanning an estimated length of 300-350 meters,
presented unique challenges with numerous special angles,
fittings, and custom cuts. Despite these complexities, the
installation was executed flawlessly, demonstrating SAR’s
commitment to excellence and expertise in handling Vahle
related installations.

TECHNOLOGIES

EMS/VAHLE RAIL TECHNOLOGY
VAHLE RAIL TECHNOLOGY
SOFTWARE SUPPORT ON SIEMENS L7 STANDARD

Date executed: 2023 – 2024

Project Description

Technical upgrade of UBS (Under Body Sealer) and NAD
(Naht Abdichtung seam sealing) robot cells.
PLC and HMI programming, robot programming using Robcad
simulation.
Mechanical and electrical intergration of new dosing
equipment (dosing systems and application guns by SAR
GMBH).
Material supply pumps by Graco systems.

Technologies

Cell Control Technology

Siemens S7 & TIA PLCs with remote IO
Beckhoff PCs & HMIs
Festo IO for air valve control and feedback
IFM analogue distance sensors
ISRA POE cameras
SEW drives and motors.
MATERIAL & DOSING TECHNOLOGY
KUKA KR C4 robots & IPR 7th axis
Lenze drives and controllers
Graco electrical material pumps

Date executed: November 2021

PROJECT DESCRIPTION

In November 2021, SAR played an important role in the
installation of a cutting-edge particle counter system aimed at
analyzing air quality in the vicinity. This sophisticated system
is equipped to detect particles ranging in size from 5-10μm,
10-15μm, 15-25μm, to particles larger than 25μm, offering
comprehensive insights into air particulate matter.
Collaborating closely with the original manufacturer of the
PSTC1C61 system, SAR ensured that the project was
executed to meet the exact requirements of the client.
This partnership facilitated a clean integration of the particle
counter system, showing SAR’s dedication to delivering
tailored solutions that meet client satisfaction.

TECHNOLOGIES

ADVANCED SENSOR TECHNOLOGIES
SENSOR TECHNOLOGY FOR PSTC1C61
SOFTWARE SUPPORT ON S7 SOFTWARE

Date executed: December 2021

PROJECT DESCRIPTION

In December 2021, FP2 C11 underwent brownfield changes,
incorporating lifts 12LS001 and 12LS011, along with the
hydraulic lifting table 11TH013 and the chain conveyor
interface to C24. These modifications were implemented
across the paint shop at Mercedes-Benz South Africa,
representing a substantial investment of time and resources.
Numerous hours were dedicated to the commissioning and
installation of multiple conveyors, the full extent of which
exceeds what can be detailed here. Nevertheless, this project
underscores the ongoing commitment to enhancing production
processes and facilitating the seamless movement of vehicles
throughout the facility.

TECHNOLOGIES

CONVEYOR TECHNOLOGY
SIEMENS SOFTWARE TIA AND S7
ROLLER BED
SHUTTLES
TURN TABLES
HOISTS

Date executed: December 2019

PROJECT DESCRIPTION

In December 2019, with the W206 marking the latest
standard for Mercedes-Benz South Africa, SAR entered into a
collaborative effort with a partner company to finalize a
significant portion of the main assembly lines for the plant.
Among the various lines completed, the engine line. SAR was
tasked with installing 51 carriers within an EMC system,
seamlessly integrating them with both conveyor systems and
an AGV (Automated Guided Vehicle) system.
The primary objective of this line was to establish a
streamlined assembly process for the new engine,
complemented by an automated marriage system for
integrating it with the vehicle’s aggregates. This undertaking
represents a testament to SAR’s capability to navigate
manufacturing environments and deliver defined solutions to
meet the evolving standards of the client.

TECHNOLOGIES

CONVEYOR TECHNOLOGY
SIEMENS SOFTWARE TIA AND S7
ROLLER BED
CROSS TRANSFER
EMS & LJU TECHNOLOGY
EMS CARRIERS WITH LJU CONTROL
EMS RAIL WITH LJU CONTROL

Date executed: December 2019

PROJECT DESCRIPTION

In December 2019, with the W206 marking the latest
standard for Mercedes-Benz South Africa, SAR entered into a
collaborative effort with a partner company to finalize a
significant portion of the main assembly lines for the plant.
One big accomplishment was the implementation of the AGV
line. SAR undertook the installation of six AGV units into an
inductive, self-guided system integrated into the concrete
flooring.
The primary objective of the line was the marriage of vehicle
aggregates with engines and the marriage thereof into the
partially assembled bodies. The point where the engine was
mounted onto the vehicle marked a critical step in the
assembly process.

TECHNOLOGIES

AGV & LJU TECHNOLOGY
AGV CAR WITH LJU CONTROL
INDUCTIVE RAIL WITH LJU CONTROL
SIEMENS SOFTWARE TIA AND S7

Date executed: December 2023

PROJECT DESCRIPTION

In December 2023, following the Chassis to Body marriage
process, a critical operation involving the fastening of multiple
bolts in the underbody area of the vehicle was identified. At
Station 56, two operators utilized Atlas Copco bolting tools,
manipulated on telescopic arms, to fasten these bolts
manually, requiring precise positioning for each bolt.
To streamline and enhance this process, an enclosed cell was
installed featuring a split roller bed and two robots,
designated as Robot 1 and Robot 2. Positioned on either side
of the conveyor, these robots are purposed to automate the
bolt fastening task, improving efficiency and consistency while
minimizing manual labor and potential errors.

TECHNOLOGIES

PLC/ROBOT TECHNOLOGY
KUKA V KRC
SIEMENS TIA
BOLTING TECHNOLOGY
ATLAS COPCO
CONVEYOR TECHNOLOGY
ROLLER BED SYSTEM

Date executed: July 2024

PROJECT DESCRIPTION

An all-new robot cell, which will mark a milestone in
automotive manufacturing, is set to be finalized in July 2024.
This innovative system will be dedicated to handling the brake
caliper and bracket components for the upcoming P703 Ford
model.
Engineered with precision, the cell is specially designed to
handle/manipulate fully casted parts between two critical
quality check stations: the Sonic test and the Eddy Current
check. These tests are important to verify the material
composition and density of the casted parts, ensuring they
meet their defined standards to prevent any failures upon
installation.
To maintain the integrity of the Eddy Current check, a
specially crafted non-metal shuttle will be implemented,
avoiding any interference with the testing process.

TECHNOLOGIES

ROBOT TECHNOLOGY
YASKAWA ROBOT HANDELING
SIEMENS TIA PROGRAM AS MASTER
CONTROLS TECHNOLOGY STANDARD AS DESIGNED
     SPECIFICALLY FOR THE CLIENT