Who is Autocraft Solutions Group?

Autocraft Solutions Group is one of Europe’s leading OEM partners for the manufacture and remanufacture of outsourced IC engines and EV batteries, and future sustainable propulsion solutions to a global market. Our unique selling point is helping our customers outsource to us their non-core operations, by providing top OEM quality production, and saving them investment and headaches involved with keeping these operations in-house. This allows them to free up their factory space, people and investment, and helps them to focus on what they do best.

Build Engines with the Flexibility of a Human, and the Repeatability of a Machine.
Autocraft Solutions Group improved engine assembly performance with a no-fault-forward workflow that guides operators step-by-step, verifies every critical action, and creates a complete digital record for every engine.

The Challenge

In engine assembly, quality isn’t just an internal metric, it’s a commercial requirement.

OEM contract awards increasingly depend on a Tier-1 supplier’s ability to prove consistent quality control.
Manual operations make it difficult to demonstrate process standardization and repeatability at the level OEMs expect.
When critical steps rely on human memory, paper instructions, or tribal knowledge, variability creeps in, and proving compliance becomes time-consuming and uncertain.

The Approach: No-Fault-Forward Assembly

Autocraft implemented a guided assembly system designed to prevent errors before they happen. Instead of inspecting quality at the end, the process enforces correctness during the build.

No-fault-forward means:

The operator is guided through the correct sequence
The right tools and parts are confirmed at the right time
Steps are verified automatically so issues are caught immediately
Every action is documented to support OEM audits and internal traceability

What Was Implemented

A connected workflow that combines operator guidance, tool control, verification, and traceability:

Here is a clean, professional rephrasing of all ten points in consistent language and tone:

AR Work Instructions Projected onto the Engine
Operators are guided by clear, step-by-step augmented instructions displayed directly in the context of the build, reducing dependency on individual experience and eliminating missed steps.
Digital Work Instructions with Validation Checklists
Integrated digital checklists introduce validation points between tasks, ensuring that each stage is completed and confirmed before proceeding.
DC Tools Control (ESTIC)
Fastening operations are tightly controlled, with the correct socket type and tightening parameters automatically enforced as part of the workflow.
Automated Socket Selector
Operators are guided to pick the correct socket, which automatically loads the appropriate tightening program. The system prevents progression if the socket is not returned correctly.
Vision and RTLS-Based Positioning for Precise Fastening
Real-time location awareness ensures fastening is performed at the correct position on the engine, eliminating “right torque, wrong bolt” errors.
Machine Vision Workflow Verification
Automated vision checkpoints verify key assembly actions and conditions, providing objective proof of quality at each critical step.
In-Process Image Capture with Companion App
Critical build steps are documented with images captured during assembly, creating a reliable record that supports audits, warranty claims, and continuous improvement.
Pick-to-Light Bearing Selection
Component selection is guided and confirmed using pick-to-light technology to prevent mix-ups and ensure consistent, error-free builds.
Digital Birth Certificate per Engine
Each engine is delivered with a complete digital build record that links all steps, checks, images, and tool data into a fully traceable “birth certificate.”
Integration with Autocraft Systems
All production data is automatically synchronized with Autocraft’s master database via SQL, ensuring seamless connectivity and centralized reporting.

Book a demo

We chose the Ansomat Operator Guidance System because it follows McDo menu ordering configuration principles, making it simple for anyone to use. Its flexibility and ability for future scale with our product innovations were key.

Autocraft CTO

Results

With no-fault-forward assembly in place, Autocraft achieved a step-change in quality, training speed, and confidence during customer engagements.

99% first-time-right was achieved by preventing errors during assembly instead of discovering them after the fact. Training time dropped dramatically because the process itself became the trainer, guiding new operators through the correct sequence with verification at every critical point.