Project Snapshot | Global Automotive OEM

Client: Global automotive OEM – vehicle assembly line (Ford program)
Industry: Automotive assembly and factory automation
Location: Unknown
Services provided: Design support for plug-and-play vehicle assembly line controls, including line concepts, panel schematics/layouts, and standards implementation as per Ford factory automation engineering inputs
Software used: Eplan Electric P8 with advanced and custom schemes developed to match Ford standards
Key result: Standardized, plug-and-play design concept for assembly stations and panels, simplifying deployment, modification, and maintenance across the line
Duration: 18 months of detailed design support in coordination with the client’s automation team

Client & Project Background

The client’s factory automation engineering team was developing a new or upgraded vehicle assembly line and required standardized, plug-and-play control designs that complied with Ford’s engineering and documentation standards. The objective was to create reusable station templates and panel designs that could be deployed across multiple zones of the assembly line with minimal rework.

APC Engineering Services provided design support using Eplan Electric P8, implementing advanced project structures and custom schemes aligned with Ford’s standards and internal guidelines.

Challenge / Requirements

The assembly line comprised multiple stations and zones (body-in-white interfaces, trim, chassis, final assembly, and end-of-line), each requiring consistent electrical, I/O, and control concepts.
Ford’s internal standards dictated naming conventions, device coding, schematic practices, and documentation structure, all of which had to be strictly followed based on inputs from the factory automation engineering team.
The client wanted a plug-and-play design approach: standardized station and panel templates that could be replicated or adapted quickly for different models and options with minimal design effort.
All designs had to remain maintainable for plant electricians and engineers while supporting future automation enhancements.

Solution (APC approach)

1. Plug-and-play Design Concept

Developed station-level design templates in Eplan Electric P8 that encapsulated typical assembly functions (conveyors, lifts, tooling, fastening systems, safety devices, operator interfaces) following Ford’s standard structures and device coding.
Structured projects with clear function and location identifiers, enabling plug-and-play reuse of circuits and pages when adding or modifying stations on the assembly line.
Created reusable macro libraries and page templates for common assemblies so that new stations could be assembled from tested building blocks instead of redrawn each time.

2. Panel Schematics and Layouts

Prepared detailed schematics and layout drawings in Eplan Electric P8 for main PLC panels, RIO panels, operator panels, and local junction boxes associated with assembly stations, conforming to Ford’s drawing standards and content requirements.
Ensured consistent panel layouts, terminal arrangements, and wiring concepts across stations so that hardware remained interchangeable and familiar to plant maintenance teams.
Integrated safety circuits, interlocks, and interface wiring to higher-level systems in a standardized way, supporting line-wide safety and diagnostic strategies.

3. Collaboration with Client Engineering Team

Worked closely with the Ford factory automation engineering team to interpret and implement the latest standards, guidelines, and feedback into the Eplan project setup and templates.
Iteratively refined custom Eplan schemes (title blocks, device tags, reports, and project structures) to match client expectations and streamline their review and approval process.

Results & Benefits

Established a robust plug-and-play design framework: new or modified assembly stations can now be engineered by reusing standardized Eplan templates and macros, significantly reducing design effort and lead time.
Ensured compliance with Ford standards across schematics, layouts, and documentation, improving alignment with internal engineering requirements and simplifying audits and handovers.
Improved maintainability at the plant level thanks to consistent device naming, panel layouts, and documentation formats, enabling faster troubleshooting and smoother training for maintenance staff.
Provided a scalable design approach that can be extended to future model lines or plant modifications using the same Eplan Electric P8 project structures and custom schemes.

Tools & Technologies Used

Design: Eplan Electric P8 with advanced project structuring, macro libraries, and custom page/device schemes tailored to Ford’s engineering standards.
Standards & methods: Implementation of Ford-specific documentation and design requirements (as provided by the factory automation engineering team), combined with best practices in modern automotive assembly automation.
Application domain: Vehicle assembly line automation with a focus on modular, template-based design for plug-and-play deployment of stations and panels.

“APC Engineering Services played a key role in implementing our plug-and-play design concept for the vehicle assembly line. Their advanced use of Eplan Electric P8 and careful application of our Ford standards resulted in standardized station templates and panel designs that are easy to deploy, modify, and maintain. This has significantly improved our engineering efficiency and documentation quality across the line.”

Case Study