Greenfield Line Launch

Executive 
Summary

THE CLIENT

Client: Global Automotive OEM
System Integrator: One of the biggest System Integrators for OEM´s with more of 1000 engineers.

INDUSTRY

Automotive

PROJECT DURATION

9 Months

SERVICES PROVIDED

PLC Programming, HMI Programming, Commissioning

Overview

During the launch of OEM new plant in Saltillo, Mexico, the European system integrator faced a critical challenge: meeting the strict requirements of a global OEM within a highly complex seat assembly line, under severe time pressure and demanding operational conditions.

Boltronic joined the project as a strategic partner, playing a key role in PLC programming, HMI development, and commissioning, ultimately contributing to the successful validation of the line.

Key Success Factors

Advanced expertise in Allen-Bradley PLCs and HMIs 
Strong knowledge of industrial networks 
Structured testing methodologies 
Strict safety and quality procedures 
Proactive communication and customer focus

The Challenge

Cross-Cultural and Technical Alignment

Coordinating with a European integrator, overcoming cultural differences and communication barriers to ensure technical and operational alignment.

Rigorous OEM Validation Requirements

Meeting the extremely strict acceptance and validation standards of OEM to secure production approval.

Greenfield Launch in an Unfinished Facility

Executing a brand-new assembly line inside a plant still under construction, managing infrastructure gaps, weather exposure, lack of enclosure, and intermittent power supply.

High Operational Pressure and Schedule Volatility

Managing constant timeline changes, weekend work, night shifts, and project uncertainty, with the risk of delayed production start-up and increased costs.

Boltronic’s Solution

Boltronic provided highly skilled automation engineers who integrated seamlessly into the project team.

Key contributions included:

Full line commissioning
PLC logic debugging and optimization
Implementation of OEM programming standards
Ethernet/IP and IO-Link device configuration
HMI screen development and bilingual adaptation
On-site technical support, training, and validation assistance

BOLTRONIC’S

Results and Impact

Successful OEM validation by OEM

Stable and efficient seat assembly process

Strengthened trust 
between OEM, System Integrator, and Boltronic

Boltronic was the only Mexican company to remain until final delivery

Client Value

Boltronic delivered more than just technical execution. We delivered trust, commitment, and resilience under pressure.