Automotive Assembly Systems–Assembly Line for Rear Suspension Modules

Fori supplied a rear module suspension assembly line utilizing Fori Rail Guided Carts (RGC) as a conveyance and assembly method alongside two fully automatic drive-thru module alignment systems.


  • Assembly Jobs Per Hour: 45 jobs
  • Keys to Success: RGC conveyance, drive through alignment
  • Results: High build efficiency
  • Solutions: Pallet error proofing
Drive-thru Suspension Module Aligner for Automotive Assembly

The assembly line consisted of (22) RGCs, two drive-thru aligners, (16) operators and various torque tools. The product for the rear suspension module varied between all-wheel drive and rear wheel drive vehicle variations. The build pallet on top of each RGC accommodated those variants and manipulated the ride height setting of the five link suspension by manually setting the ride height wheel in the correct position verified by a switch on the pallet.

A drive-thru aligner was also utilized within the system to help streamline the process. A lift and locate unit was located in each drive-thru aligner that would pick the pallet from the RGC and accurately present the suspension assembly for alignment.

Utilizing Fori’s RGCs allowed for a timelier changeover. The RGC system also provided long term flexibility supporting:

  • Accommodating future product changes that could add new stations.
  • Production increases that can affect station to station cycle times.
  • Production line shape if required.
Fori Rail Guided Carts (RGC) with Custom Tooling Pallet

For more information about Fori Automation’s RGCs and assembly systems, please visit our website.


Fori Flex Floor Product Line for Flexible Assembly & Material Handling Systems

Fori Automation, a global leader in the design, build and integration of material handling, assembly, testing and welding systems has further expanded its assembly and material handling product lines. Fori has added a new material handling platform to its ever growing product line to help facilitate material flow through today’s manufacturing facilities.

The Fori Flex Floor product line is a flexible material handling and assembly system that is designed to fit around the customer process and product, whereas many of the other material handling products on the market require the customer process and product to fit around the material handling system. The Flex Floor platform includes a variety of vehicles based on the same architecture that have varying levels of capability depending on the end users specific needs.

Fori - Flex Floor Logo

The Fori Flex Floor utilizes a heavy duty extrusion style frame that enables the footprint of each style vehicle to be modified to fit the product being assembled or the materials being moved. The Flex Floor platform utilizes commercially available drive wheels, casters, batteries, controls components and guidance. The Flex Floor platform is based on a Siemens Safety PLC based architecture, providing the end user an open architecture. Many of the other products on the market include a “black box”, requiring the user to enlist support from the equipment supplier. Each assembly and material handling system can be supplied with a Fori Vehicle Management System (VMS), enabling the system to be fully autonomous, only requiring input for scheduling of moves either from the user or from the plant production system, the Fori VMS takes care of the rest. The Flex Floor vehicles 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 or part. Additionally, each vehicle is designed to be user friendly and virtually maintenance free for the end user.

Fori Rail Guided Carts RGCs for Automotive Module Assembly Systems
Example of Fori Flex Floor – Rail Guided Cart (RGC)  utilized for a Corner Module Assembly Line

Flex Floor – RGC: Flex Floor Rail Guided Carts (RGCs) are a direct replacement for traditional, monument based conveyor systems that are typically utilized in assembly processes. Fori RGCs utilize a low profile, floor mounted rail for tracking and a single, suspended drive wheel to propel the vehicle through the assembly process.

Fori - Flex Floor Rail - Flex Floor Rail Guided Carts (RGCs) for Module Assembly Systems

Flex Floor 1.0: Flex Floor 1.0 is a cost effective, scalable Automated Guided Cart (AGC) that is used for a variety of applications, including assembly and material transport. The vehicle includes a single drive wheel, perfect for loop style assembly and material handling systems.

Fori - Flex Floor 1.0 - Module Assembly Automated Guided Cart (AGC)
Flex Floor 2.0: Flex Floor 2.0 is based on the same platform as the Flex Floor 1.0, but provides more capability by utilizing dual drive wheels. The results are a vehicle with double the capacity and Omni-directional capability. The vehicle is capable of spinning on its center and moving laterally, resulting improved layout flexibility and the capability to transport larger assemblies, such as large truck frames.

Fori - Flex Floor 2.0 - Module Assembly Automated Guided Cart (AGC)
Flex Floor 2.0T: Flex Floor 2.0T is a Tunnel style AGC that utilizes the same architecture as the Flex Floor 2.0, but also includes (2) electric hitch pins that are utilized for transportation of companion carts. These companion carts are utilized for material transport and can include a variety of attachments, including roller conveyor, lift tables and powered trunnions.

Fori - Flex Floor 2.0T - Tunnel Style - Material Handling - Automated Guided Cart (AGC)

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.