How Skoda uses smart manipulators to ease heavy car assembly

Skoda workers handle heavy parts with ease thanks to smart manipulators, boosting safety, ergonomics, and production speed. Discover how tech meets precision.

At first glance, workers on the Škoda production line may seem to possess superhero-like strength. With remarkable ease, they handle massive vehicle components. But the true force behind their efficiency lies in the seamless integration of cutting-edge technology into daily operations.

Take the 21-inch Supernova alloy wheels, for example. Weighing over 30 kilograms with the tyre, these wheels are mounted in mere seconds—by a single person. This feat is made possible by a combination of electric and pneumatic manipulators. These tools don’t replace workers; they amplify their abilities. Sensors detect hand pressure and motion direction, allowing the systems to adjust in real time for precise and safe handling.

With this setup, an operator can help fit up to 440 cars in a single shift—mounting nearly 900 wheels weighing up to 25 tonnes in total. Such physical demand would be unsustainable without these tools. That’s why Škoda emphasizes ergonomics throughout the production process. As workplace ergonomics coordinator Lucie Vacková explains, legislation allows no more than 10 tonnes to be lifted per worker in an eight-hour shift. Škoda ensures compliance with this limit through standardized use of supportive technology.

Efficiency doesn’t come at the cost of safety. On the contrary, Škoda has developed specialized tools—such as a five-arm bolt-tightening device that looks like it came straight from a Formula 1 pit stop—which accelerate tasks while eliminating error potential. Elsewhere on the line, a 60 kg dashboard or a 40 kg door can be precisely installed by a single operator, thanks to meticulously designed support systems.

All of this is part of a broader initiative: Škoda’s integration into Volkswagen Group’s Industry 4.0 strategy. The company already deploys autonomous mobile robots and is exploring collaborative robots (cobots) to work safely alongside humans. This direction reduces injuries, enhances worker well-being, and increases overall output quality.

Under the GreenFuture program, Škoda also aims to halve its environmental impact per vehicle by 2025 compared to 2010 levels. By combining digital innovation, ergonomic safety, and sustainability, Škoda is not only optimizing manufacturing—it’s reshaping it. These investments reflect a deeper commitment to responsible industry, where human energy and smart machines operate as one.

Source: skoda-storyboard.com