Advanced assembly

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