Automated Assembly Lines for the Automotive & Non-Automotive Industries

Fori Automation specializes in the custom design, build and integration of automated assembly lines for a variety of industries and products.  Fori has supplied assembly lines for the automotive, construction and recreational vehicle industries.

Our dedicated assembly and automation group has the experience to process a wide range of assembly systems across nearly any industry. Our assembly systems include: Axle, battery pack, bullet manufacturing, cockpit, door, electric stator, engine dress, glass roof, headliner, seat, motorcycle front end & saddle pack, electric scooter and many others.

Fori’s main system verticals which include, automated assembly, material handling, robotic welding and testing, enable us to be a one stop equipment supplier for the entire assembly system. Within the main system verticals, include vast experience with error proofing, data collection, MES integration, lift assists, auto-torquing and robotic handling.

Our latest material handling systems, such as our Rail Guided Carts (RGCs) or Automated Guided Carts (AGCs) have been a differentiator for our Tier 1 and OEM customers from a flexibility and scalability perspective versus a traditional conveyor system.

RGCs and AGCs improve tear down and setup times and also allow the end user to scale their material handling system based on projected production rates. The ability to re-utilize their capital expenditure on future programs through a simple tooling change is another long term benefit.  Below is a success story where one of automotive Tier 1 customers utilized a fully automated assembly line with RGCs for their assembly system.

For more information on Fori Automation’s available products and automated systems, please visit our website.

Automated Material Handling Products for the Automotive & Non-Automotive Industries

We are proud to announce that we have added (4) automated material handling platforms to help facilitate material flow through today’s manufacturing facilities.

These developments include Automated Tuggers, Powered Drive Wheel Systems, High Capacity AGVs and Synchronization of automated vehicles for the transport of large tooling.

The systems are designed to increase safety, throughput and accuracy and are supplied to replace traditional material handling methods such as fork lifts, manned Tuggers and overhead cranes. The systems are fully configurable to vary the level of automation depending on the requirements of the end user. The AGV control can be as simple as utilizing a control pendant to manually move the vehicle, all the way up to the highest level of automation which includes a Fori Vehicle Management System (VMS) or Traffic Control. A VMS allows the system to be fully autonomous, only requiring input for scheduling of moves, the VMS takes care of the rest.

Fori’s software is based on a Siemens Safety PLC for the vehicle control, providing an open architecture for the end user. Utilization of the Safety PLC based system eliminates the “black box” supplied by many of the AGV companies in the industry. All Fori AGVs are outfitted with the latest safety components available on the market. At a minimum the vehicles are supplied with perimeter Safety Scanners, Indicator Lights, Alarms and E-stops. The Safety Scanners provide collision avoidance for the end user to ensure safety for the operator and that no damage occurs to the product. Additionally, each vehicle is designed to be user friendly and virtually maintenance free for the end user.

Automated Tuggers: Tuggers are a direct replacement for Fork Lifts. The vehicles are utilized for transporting carts, kits and various product throughout the manufacturing process.


Powered Drive Wheels: Powered Drive Wheels are modular drive wheel sets that are mounted to mobile tooling or operator platforms for automated mobilization. The systems utilize a standard control architecture that is expandable to support added powered drive wheels in order to increase capacities.

Fori Automation - Powered Drive Wheels for Platform & Tooling Mobilization
Fori offers a variety of Powered Drive Wheels with a wide range of capacities that can be mounted to tooling or operator platforms for automated guidance.


High Capacity AGV: AGVs are used for a variety of applications that are traditionally completed with an overhead crane. Fori AGV capacities are upwards of 250,000 lbs.


Synchronized AGVs: When required multiple vehicles can be synchronized to move large tooling, this methodology allows a single, modular vehicle design to be provided to the end user, but multiples of two or three vehicles can be used for lift and carry of various tools.


Fori Automation, Inc. privately held and U.S. owned and operated since 1984, specializes in the custom design, build and integration of automated material handling, assembly, testing and welding systems for the automotive and non-automotive industries. With over 30 years of experience and seven locations across four continents, we are positioned to support our customers around the globe.

For more information of Fori Automation’s products and capabilities, please visit our website.


Automotive Assembly Line + Fori Assembly System + Scooter & Motorcycle Assembly

Automotive Assembly System – Battery & Scooter Line

Fori recently integrated a flexible assembly system for a scooter assembly line. The line currently utilizes a scalable manufacturing methodology, enabling the end user to increase automation as production requirements increase.

The assembly system is made up of a single assembly loop and two offline stations. The two offline stations consist of a battery assembly area, along with a tire & wheel assembly area.

A unique characteristic about this assembly loop is the manual carts are tied into a track that resides on the floor similar to the Fori Flex Rail system that utilizes Rail Guided Carts (RGCs).

The unique equipment provided includes:

  • Flexible production tooling pallets
  • Bushing press
  • Heavy duty torque tube for front fork attachment
  • Robotic sealant dispensing cell
Automated Sealant + Fori + Assembly Systems
Automotive Assembly System – Automated Sealant Apply

Implementation of these types of scalable assembly systems allow the end user to minimize upfront expenditure and utilize a cash flow structure which supports increased automation as throughput requirements increase.

For more information on Fori’s available equipment, please visit our website.


Robotic Assembly + Automated Assembly + Module Assembly + Rail Guided Cart + RGC

Fori Flex Rail – Rail Guided Cart (RGC) Assembly System for Rear Suspension Modules

A Fori Flex Rail system, utilizing Rail Guided Carts (RGCs) was recently supplied for a rear suspension module build. The system consisted of a main build line, two module alignment machines and a final assembly build line.

The utilization of a Flex Rail System and Rail Guided Carts provides the utmost flexibility for those customers who need to be able to accommodate change easily. The ability to be flexible in the automotive world means less downtime, cost and reduced infrastructure during installation.

Rail Guided Cart based assembly systems are becoming the norm on Fori’s Automotive Assembly Systems. The systems can be modified easily, whether it be adding a station or even accommodating fluctuations in throughput requirements.

Automation + Module Assembly + Module Aligner + Wheel Alignment
Fori Flex Rail System – Rail Guided Cart Assembly System with Integrated Robots

Each Rail Guided Cart is a stand along unit with an integrated Siemens Safety PLC and Wireless Client. Utilization of the PLC based system, results in an open architecture to the end user. Each of the carts are outfitted with safety bumpers and collision avoidance laser scanners to ensure the safety of the operators. A video of the Fori Rail Guided Cart can be found here.

Overhead support to the operators for tooling in most cases are simple jib booms and inverted “L” posts that are bolted to the floor to promote flexibility of the system. In instances where sequence and repeatability are critical, a robot is integrated for final torquing and the load and unload of assemblies.

Benefits of the Fori Flex Rail Systems utilizing Rail Guided Carts include:

  • Increased safety
  • Improved part and assembly access
  • Decreased plant infrastructure
  • Reusable for future programs
  • Scalable solution – add or remove carts for production fluctuations

For more information on Fori Rail Guided Carts please visit our website or contact us at

AGVs, Automated Guided Vehicles, Automated Material Handling, Aerospace AGVs, Heavy Duty AGVs, High Capacity AGVs, Custom AGVs

Automated Guided Vehicles for Aerospace Assembly System

Fori Automation, Inc. designs, builds and integrates custom assembly and material handling systems for the Aerospace industry. Fori recently provided a turnkey Automated Guided Vehicle (AGV) system for a large Aerospace OEM. The assembly system utilized a moving line methodology.

Automated Guided Vehicles
Fori Automation Automated Guided Vehicle (AGV) for Aircraft Assembly and Material Handling

There were a number of design considerations for the AGVs provided. The AGVs were built with an emphasis on operator access and ease of use. The AGVs included integrated scissor lifts for cockpit assembly, as well as other operator platforms that aided in the assembly of the aircraft. The vehicles were required to move at very slow speeds, sometimes as slow as 20″ per hour. The system utilized a high voltage servo based controls architecture in order to meet the accuracy and speed requirements for the project.

A total of (18) Fori Aerospace AGVs were supplied for the system. A video outlining the manufacturing and assembly methods used for the aircraft assembly can be viewed here.

For more information please visit Fori Automation’s website.