Company overview

WABCO is a global leader in the automotive industry, specialising in advanced technologies for commercial vehicles. The company manufactures vacuum pumps that support suspension systems, braking assistance, and fuel systems, delivering high standards of safety and performance.

Executive summary

The implementation of the new vacuum pump production line has delivered significant benefits for WABCO, including:

• Increased production capacity and flexibility.
• Improved product quality and process reliability.
• Enhanced operator safety and ergonomics.
• Full compliance with Industry 4.0 and safety standards.
• Comprehensive documentation and CE certification, supporting ongoing operational excellence.

Project objectives

As part of a production transfer between plants, WABCO required a new production line that would:

• Meet Industry 4.0 standards.
• Achieve the required design capacity.
• Ensure flexibility for assembling several pump variants.
• Provide full process control and traceability.
• Improve workplace ergonomics.

The challenge

WABCO needed a modern, fully integrated production line capable of assembling multiple vacuum pump variants while maintaining high efficiency and quality. The new line had to comply with Industry 4.0 requirements, including advanced process monitoring, traceability, and operator support. Additionally, the line needed to minimise changeover times and ensure ergonomic workstations.

The solution

A complete production line for vacuum pumps was designed and delivered, consisting of 12 stations that maintain the required assembly cycle and enable the free flow of components. Key features of the solution included:

• Integration of vision systems (KEYENCE) to ensure correct assembly and provide real-time quality control.
• Recording of all process parameters (TOX, Baltech) for comprehensive process monitoring.
• Active Poka-Yoke systems on each socket, with proximity sensors, replaceable sockets, and operator feedback software to support quick and error-free changeovers.
• Ergonomic design of individual workstations to improve operator comfort and efficiency.
• Use of SIEMENS PLC controllers and Profinet network for seamless communication between stations.
• Safeguards to prevent operators from skipping assembly steps, supported by HMI software for operator communication and monitoring.
• Implementation of TOX and BalTech pressing systems for precise process control and integration.
• Oil spray system using Vectolub SKF micropumps for optimal lubrication.
• Step-by-step software sequences and master part checking for robust control functions.
• Communication with a central traceability base, using PC and LabView software, to register process parameters for each assembled unit.
• FESTO pneumatics for reliable operation and easy maintenance.
• Pallet system for safe and efficient component flow.
• Compliance with safety directives, including limit switches and current protection.

A comprehensive installation was completed at WABCO’s facility, with full support provided during the configuration of test parameters. Complete documentation, including risk analysis and a user manual, was delivered. Following commissioning and successful testing, the line was granted CE certification.

Key achievements

Industry 4.0 compliance

The new line meets advanced standards for process monitoring, traceability, and operator support.

Flexible, efficient assembly

The line supports multiple pump variants, with active Poka-Yoke systems and minimal changeover times.

Comprehensive process control

All process parameters are recorded and monitored, ensuring consistent quality and full traceability.

Enhanced ergonomics and safety

Workstations are designed for operator comfort, and the line includes robust safety features.

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