Advanced assembly

Establishing flexible and stable product assembly operations which output complex products to help our clients achieve their premium product aspirations.

Advanced assembly


Niche volume battery assembly service for specialist powertrains bespoke to the requirements of our clients.

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Contact us to learn more about our e-machine assembly services.

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Fully assembled and integrated bespoke electric drive unit (EDU) solutions for niche volume vehicle applications.

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Complete full vehicle build service or sub-system integration for niche volume production.

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Contact us to learn more about our ICE powertrain assembly service.

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Dedicated kitting service providing ready to go solutions for vehicle production or after-market supply.

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Bringing high performance vehicles to market by providing a flexible assembly approach to support low volume powertrain and drivetrains.

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Our highly customisable, off-the-shelf transmissions for high-performance and specialised electric vehicles are available as an off-the-shelf baseline product  or tailored to bespoke requirements in remarkably short lead-times.

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Make Ricardo your advanced assembly partner

Quality management

We assemble product using the highest levels of quality management ensuring that our clients receive a quality assured product with low levels of in-service failure.

Full-service capability

We offer end-to-end product design, development, production, and testing capability. Trusting Ricardo with the full product development process simplifies our clients’ supply chains and gives more control over the final product.

Flexible design options

We can develop solutions in-house or specify assembly lines for products designed by our clients, making our service as flexible to meet their exacting standards.

Multi-industry expertise

We have significant assembly and engineering expertise across a range of industries, from motorsport to high-performance vehicle. Our services are available to support the automotive, motorsport, aerospace, and defence markets to deliver niche production.

Advanced assembly


Book a consultation with our advanced assembly experts

Our niche volume series production assembly lines offer our clients a high-quality, process-controlled solution for their products.

Our services range from single prototype builds through to a highly automated production lines, delivering thousands of units per year. We set-up and manage supply chains and ensure that all products meet exacting quality standards and specifications as set out to us by our clients and industry standards.

Our assembly capability can deliver niche volume programmes of any size, from single prototype builds through to a highly automated production lines outputting thousands of units annually.

This capability has been proven to withstand challenges in volume and rate associated with global economic variability.

We combine state-of-the-art assembly facilities and the development, qualification, and management of a quality-assured, sustainable supply chain to help our clients achieve their premium product aspirations.

Our advanced assembly services are delivered by a dedicated and experienced team who execute a New Product Introduction framework using our proven tools and techniques and commence series assembly.

We engage with our clients early in the process to optimise an assembly solution for maximum ROI.

We use high levels of automation and no-fault-forward checking. Our assembly line is geared up for maximum efficiency and responsiveness to the ever-changing demands of the marketplace. Adapting, where possible, the latest thinking in production scheduling and lean techniques, means that customers are comfortable to commit to Ricardo, programme after programme.

Our clients are numbered amongst some of the biggest names in the high-performance and motorsport industries, including:

  • McLaren
  • Aston Martin
  • Bugatti

We work with OEMs and tier-1 suppliers who require assembly solutions for complex and specialised products in niche volumes. From specialist vehicles to medical grade technology, we are well positioned to assist with the development of an assembly programme for your specialised products.

Our niche volume assembly line at our headquarters in Shoreham-by-Sea averages 100 engines per week which are continuously assembled and tested to the most exacting OEM standards.  Our quality-focussed assembly line with high levels of automation and in-process checking to maximize 6-sigma performance.

Facility overview

The facility incorporates best practice lean manufacturing principles and is a showcase for Ricardo know-how.

  • 13 station assembly process
  • 10 station main assembly line plus;
  • Break-in pass-off (BIPO) rig/de-rig
  • BIPO cell
  • 88-point pre-delivery inspection (PDI)
  • 6 station cylinder head sub-assembly line
  • 45-minute Takt time
  • Single Piece Flow (1 engine per station)
  • Minimal in process stock
  • Line-side delivery of components into flow racks
  • 2,000 engines per year (single shift)

Main line assembly process

  • Human-machine interface (HMI) at each station
  • Contains work standard
  • Automatic indication of tool selection
  • Tracks build and cycle time status
  • DC tools at each station
  • Sets fastening programmes automatically
  • Measures rundown rotations, angle and torque
  • All rundown results saved to the database against engine number - full birth history 
  • Operator must accept each operation by pressing “step complete” button
  • Pneumatic interlock will only release if all work steps completed
  • Light curtain control for bearing selection
  • 2D liquid gasket plotter interlocked to main line 

BIPO cell

  • Motoring dyno
  • Auto dock/undock 
  • Auto oil/coolant fill
  • Pre-heating of fluids
  • Safety systems:FM200 fire suppression system
  • Smoke and flame detectors
  • Explosion protection

Quality systems

  • 3 focused quality gates (3, 7 and 10)
  • Integrated quality systems into every station
  • Poke-yoke error-proofing
  • DC tools
  • Traceability through serialisation and lot control
Manufacturing Assembly Line

Discover our case studies

DS Performance

Developing a transmission for Formula E

Read case study
Rodin FZERO Gearbox

Developing cutting edge gearbox for one of the world's fastest single seater track car

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Hyundai I20 N Rally2 Car

Development of hybrid 4wd transmission

Read case study

Advanced assembly Resources

Ricardo employees named in 2024’s The Manufacturer Top 100 list

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Ricardo at Professional MotorSport World Expo 2023

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Ricardo at MIA CTS23 - Motorsport Engineering & Technology Show

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Defence and Security Equipment International (DSEI) 2023

Read event

Meet the experts

James Sundler

James Sundler

Business Development Director

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Steve Blevins

Steve Blevins

Head of Engineering for Motorsport

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Stuart Cooper

Stuart Cooper

Market Head - Motorsport

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Tony Golland

Tony Golland

Market Head - Defence

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