Automotive / SUV / Truck Sub-assembly

As an important part of our synchronous contract-manufacturing-support for automotive and truck original equipment manufacturers (OEM), Comprehensive Logistics (CLI) builds a variety of highly complex sub-assemblies at multiple manufacturing-support operations. We perform sub-assembly for:

Our synchronous sub-assembly services are engineered to accommodate the most complex product configurations.

We have excelled at the most complex sub-assemblies, ranging from three to almost 100 build variations. CLI builds more than 2.5 million combined automotive, truck and SUV sub-assemblies annually including electric vehicles. Depending on the type of sub-assembly, we use a variety of assembly methods, including:

Fully automated builds using robotics and programmable logic controller systems.
Conveyor built, which combines manual and robotics assembly, positioning, torque monitoring, and programmable logic controller systems.
Sequenced, step-by-step manual station builds.

How does our sub-assembly process work?

A pull signal from the OEM initiates the integrated multipart pick processes.
Fully integrated ERP and line controllers tie line-side parts location, consumption, and error-proofing into a synchronous, transparent system.
Disciplined process controls ensure compliance with stringent quality standards.
Error-tolerance detection adheres to OEM-defined standards, including tolerances as small as 40 microns—a length smaller than the diameter of a human hair.
Completed sub-assemblies are off-loaded and placed into specially designed reusable containers for lineside delivery at the OEM’s assembly plant.

Error Proofing

All of CLI's synchronous sub-assembly operations adhere to a precise error-proofing process, which includes these tools and techniques:

Scan guns, pick lights, and light screens ensure that correct parts are configured and installed accurately every time.
Vision systems, laser-placement guides, and proximity sensors detect correct part presence, location, and orientation.
Predictive capability uses statistical process control software to collect data.
Torque and torque angle readings are tied to final assembly barcode labels.
Assembly tools are calibrated once per shift.
Master part gauges use digital probes to allow for adjustments.

Through millions of builds involving multiple variations and meticulous error-proofing, CLI has perfected our sub-assembly processes to ensure the highest quality standards and precision for automotive and truck OEMs.