OEM AND TIER 1 BROWNFIELD AUTOMATION
When production cannot stop, the AMR supplier has to be more than a robot vendor.
A browser-ready research paper for US and European sourcing, engineering, MP&L, IT manufacturing, safety, innovation, and executive teams evaluating brownfield AMR and autonomous forklift programs.
Chery Dalian Scope
484 AMRs
Final Assembly Footprint
100,000+ m2
Production Takt
Up to 72 JPH
Line-side Call Points
750
Executive Summary
The EV transition has created two very different automation markets.
The first is the visible market: greenfield EV plants, battery plants, and clean-sheet logistics systems. These sites are easier for AMR suppliers because the building, routes, buffers, chargers, line-side areas, IT architecture, and safety zones can be designed around automation from the beginning.
The second is the decisive market: brownfield OEM and Tier 1 plants. These are existing sites that must be transformed while they continue to build vehicles, ship parts, protect takt, satisfy safety governance, and manage legacy IT/OT systems. In these plants, the question is not “Can a robot move from A to B?” The real question is: “Can the supplier protect production while changing the operating system of internal logistics?”
ForwardX Robotics has a rare and highly relevant proof point: Chery Dalian. The project was not a showroom pilot. It was a large brownfield final-assembly logistics program in an existing automotive factory. The provided project materials show:
- • Existing older plant environment, with partial floor renovation needs.
- • About 100,000 m2 final-assembly logistics scope.
- • Production takt designed for up to 72 JPH across Line 1 and Line 2.
- • Two current vehicle models, T1EJ and T19, with future multi-model expansion expected.
- • Material flows covering bulk receiving, warehousing, line-side delivery, SPS cart delivery, BOX direct supply, small parts kitting, PACK units, powertrain components, cooling module parts, and empty container loops.
- • Customer Wi-Fi network rather than a purpose-built greenfield network.
- • RCS integration with the customer’s logistics business system for inventory management and call-for-material functions.
- • Hardware integration with robotic arms, skateboard conveyors, and existing magnetic-strip AGVs.
- • Contract scope including 484 AMRs, 107 automatic chargers, 750 line-side call button boxes, 18 dispatch software sets, servers, displays, PDA devices, QR code labels/protection, reflective strips, and implementation toolkits.
- • Contracted project scope included design, manufacturing, transport, unloading, placement, unpacking, installation, commissioning, training, production support, and technical service.
For US and European readers, this matters because many future automation opportunities will not be clean-sheet EV megasites. They will be battery-module areas added to existing plants, ICE assembly plants converted to EV/hybrid production, body shops adapted for new platforms, stamping shops feeding mixed portfolios, Tier 1 plants forced to support more volatile demand, and MP&L teams asked to reduce forklifts without taking a plant down.
ForwardX should be positioned as the brownfield AMR specialist for automotive because it combines five capabilities that must exist together:
- 1. A broad AMR/AGF portfolio, from compact lift AMRs to 2500 kg-class carrier AMRs and autonomous forklifts. 2. Multi-modal navigation and perception, including vision, LiDAR, QR code, lane-line recognition, and semantic understanding. 3. Fleet software that supports mapping, task orchestration, traffic control, API integration, dashboarding, diagnostics, and exception recovery. 4. Automotive project management that supports phased deployment, fragmented installation windows, incremental mapping, pilot-to-scale rollout, and production ramp support. 5. Change-management discipline that converts experience-driven logistics into system-driven logistics without losing plant trust.
The thesis is simple:
Greenfield projects prove a robot can operate in a planned environment. Brownfield projects prove a supplier can transform a live production system. ForwardX has proven the second.
Download the Full White Paper to Explore:
• 484 AMRs in Live Production
• One of the World’s Largest Deployments
• Brownfield Automation Challenges
• Production Continuity Strategies
• Legacy System Integration
• OEM & Tier 1 Best Practices