From design to delivery: How automation is revolutionising the EV value chain

Automation has significantly impacted the electric vehicle (EV) supply chain, from design to delivery. Automation can improve efficiency and productivity apart from keeping consistency in the manufacturing process, making it possible to produce more EVs at a lower cost. The most important aspect of automation will be to de-skill the entire manufacturing process, making workforce availability easy.

As technology continues to evolve, automation will likely play an even more significant role in the future design, production, and delivery of EVs, writes Mukund Shah – CEO of Affordable Robotic & Automation Ltd. (ARAPL).

According to a report by the International Energy Agency (IEA), the number of electric cars on the road surpassed 10 million in 2020, up from just a few thousand in 2010. The report also highlighted that the global stock of electric passenger cars, light commercial vehicles, and buses increased by 43% in 2020, despite the Covid-19 pandemic. Furthermore, the global electric vehicle market size is projected to grow from 3.2 million units in 2020 to 26.9 million units by 2030, at a compound annual growth rate of 29.1% during the forecast period, according to a report by Markets and Markets. This growth is expected to be driven by factors such as government initiatives to promote EVs, technological advancements in batteries and charging infrastructure, and rising consumer awareness about the benefits of EVs.

Automation is playing a vital role in the revolution of the electric vehicle industry. Here are some ways in which automation is driving this revolution:

– Battery production: The production of high-performance batteries for EVs requires precision and accuracy. Automation is being used in battery production facilities to ensure consistency and quality. For example, Tesla’s Gigafactory 1 in Nevada is highly automated and capable of producing batteries for up to 500,000 vehicles per year.

– Autonomous vehicles: Several EV manufacturers are developing Autonomous driving technology to improve safety and efficiency. For example, Tesla’s Autopilot system uses a combination of cameras, radar, and ultrasonic sensors to enable autonomous driving on highways.

– Manufacturing processes: Automation is also being used in the manufacturing process for EVs to increase efficiency and reduce costs. For example, the Volkswagen Group’s Zwickau plant in Germany is an entirely automated factory that can produce up to 330,000 electric vehicles annually.

Revolution Of EV Supply Chain Through Automation

The electric vehicle supply chain is being revolutionized by automation, transforming how vehicles are designed, manufactured, and delivered to consumers. From the production of battery cells to the final assembly of vehicles, automation drives innovation and efficiency across the entire EV supply chain.

Here are some ways that automation is revolutionizing the entire EV supply chain:

– Robotics: Robotic automation can be used in various stages of the EV supply chain, such as assembly, painting and warehouse automation. Automating these tasks makes the manufacturing process more efficient, consistent, and less prone to human error. For example, ARAPL Raas uses Intelligent Software (WCS, ECS, ROS, QR) with Robots (Flying Shelves, AGV, ACR) in warehouse Automation.

– Automated Guided Vehicles (AGVs): AGVs are autonomous vehicles that transport materials around a factory or warehouse without human operators. They can transport parts and components within a factory, reducing the need for manual labour and improving material flow. For example, the BMW factory in Leipzig uses AGVs to move parts and components to assembly stations.

– Machine learning and AI: Machine learning and AI can optimize the manufacturing process by forecasting demand, scheduling production and optimizing inventory levels. Manufacturers can make more informed decisions and reduce waste by analyzing data from multiple sources, such as sales forecasts and supplier lead times. For example, Toyota uses AI to optimize production at its Takaoka plant in Japan.

– 3D Printing: 3D printing can produce parts and components on demand, reducing the need for inventory and storage. This can also reduce lead times and improve flexibility in the supply chain. For example, Volkswagen uses 3D printing to produce metal parts for its electric vehicles, such as the ID.3.

– Supply Chain Visibility: Automation technology can track products and materials throughout the supply chain, providing insight into inventory levels, shipment status and other key metrics. This can help manufacturers optimize their supply chain and reduce waste. For example, ARAPL uses supply chain technology to provide assembly line automation for the automobile industry so that its products are ethically sourced.

Overall, automation technology can help manufacturers reduce costs, improve quality and increase efficiency in the EV supply chain. By adopting these technologies, manufacturers can remain competitive in the rapidly growing EV market.

Areas Leveraged by Automation in EV Supply Chain

The electric vehicle supply chain is one area where automation is being leveraged to increase efficiency, reduce costs, and improve quality. Here are some areas within the EV supply chain where automation is being used, along with examples and statistics:

– Electric Motor Manufacturing: Automation is also being used in electric motor manufacturing to improve quality and reduce costs. For example, ABB Robotics has developed a fully automated production line for electric motors that can produce up to 10,000 motors per year with a single operator. The company claims that this production line reduces costs by up to 25% compared to traditional manufacturing methods.

– Charging Infrastructure:  Automation is being used to improve the efficiency and reliability of charging infrastructure. For example, ChargePoint, one of the largest EV charging networks in the world, uses cloud-based software to monitor and manage its charging stations remotely. The software can detect and diagnose issues, perform updates, and optimize charging rates to reduce user wait times.

– Logistics and Distribution:  Automation is being used to improve the efficiency and speed of logistics and distribution in the EV supply chain. For example, electric vehicle maker Rivian has partnered with Amazon to develop electric delivery vans equipped with autonomous driving technology. These vans are designed to improve delivery speed and reduce emissions, and they are expected to begin operating in the next few years.

Overall, automation is playing a significant role in improving efficiency and reducing the cost of the EV supply chain. As the EV market grows, we expect to see even more automation in these areas and others within the supply chain. However, it is essential to note that automation technology is not a one-size-fits-all solution. Each company must evaluate its unique needs and requirements before implementing automation technology. Additionally, companies must ensure they have the necessary infrastructure, skilled workers, and adequate training programs to support automation technology. Overall, the EV industry is on a path to significant growth, and automation technology is crucial in achieving this growth. It will continue to play a vital role in the design, production, and delivery of EVs, and companies that embrace it will undoubtedly reap the benefits.

With the rapid growth of the EV market and the increasing demand for EVs, automakers and suppliers must continue to invest in automation technology to remain competitive. This will ensure that they can meet the demand for EVs while reducing their environmental impact and improving their bottom line.