Kuka Robotics

Overview Challenge Solutions Benefits

To handle continuous production for Chrysler Group's Jeep Wrangler, KUKA Systems Group needed an automated manufacturing solution that would connect assembly-line robots with a controller, multiple devices, applications and back-end systems. The company implemented an intelligent system anchored by Windows Embedded and Microsoft SQL Server that controls 246 robots and produces more than 700 car bodies each day. The new solution added flexibility to the manufacturing process, provided continuous uptime and increased visibility.

Benefits at a glance

  • Builds the body of the Jeep Wrangler in 82 seconds
  • Operating 246 robots across 60,000 points on the floor
  • Ten SQL Servers manage a constantly changing, complex data flow

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KUKA Robotics Corporation—designer of the first industrial robot in 1973 and one of the world's leading suppliers of robotics—sought to design an automated manufacturing process capable of producing eight different Jeep Wrangler bodies on the same production line without interrupting production flow.


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Using software platforms from Windows Embedded, Microsoft SQL Server and the Microsoft .NET Framework, KUKA designed a solution that controls 246 robots and supports 1,444 nodes that can connect with approximately 60,000 devices on the shop floor to produce 700 car bodies each day.


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Rapid adaptation supports multiple models and helps KUKA produce a car body every 82 seconds. The system makes possible continuous uptime, with 20 hours of production per day for more than six years, and the familiar interface improves efficiency and reduces training time.


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