As commercial vehicle manufacturers accelerate the transition to zero-emission transport, assembly quality, traceability, and operator safety become increasingly critical. Ansomat partnered with DAF Leyland Trucks through the ZETTA (Zero Emissions Truck Testing Automation) programme to deliver an advanced operator guidance solution for EV battery assembly, helping create a scalable, error-proof manufacturing process.
Using digital work instructions, intelligent tooling, machine vision, and real-time validation, the solution ensures every assembly step is completed correctly while providing complete production traceability.
The ZETTA (Zero Emissions Truck Testing Automation) project brought together leading industry and innovation partners to accelerate the adoption of battery-electric commercial vehicles.
Ansomat’s contribution focused on delivering a precision-controlled, operator-guided assembly system, using assembly work instructions to drive accuracy, safety, and repeatability in a high-voltage EV battery environment.
Electric vehicle battery packs require highly controlled assembly processes where even small mistakes can compromise quality and safety.
DAF Leyland Trucks needed a solution that could:
Two-Station Smart Assembly System
We designed and deployed a two-station EV battery assembly solution, combining operator guidance, digital work instructions, and real-time validation into a seamless workflow.
Each station was engineered to:
The production system combines connected hardware and software to create a fully guided assembly environment for electric vehicle battery production.
Key components include:
Together, these technologies provide real-time operator guidance, automatic process validation, torque control, production data capture, and end-to-end traceability throughout the battery assembly process.
Using Real-Time Location System (RTLS) technology, the solution continuously monitors tool position during assembly.
This ensures:
Integrated machine vision systems automatically verify critical assembly steps and component placement before production can continue.
Benefits include:
The assembly solution is fully integrated with the Manufacturing Execution System (MES), creating a digital record of every production step.
The platform automatically captures:
This enables complete visibility across the entire EV battery assembly process while supporting quality assurance and regulatory compliance.
Interactive digital work instructions provide operators with clear, visual guidance throughout every stage of assembly.
By replacing static paper documentation with intelligent operator guidance, manufacturers benefit from:
See how DAF Leyland transformed electric truck battery assembly by replacing manual processes with an intelligent digital operator guidance platform that improves safety, quality, and traceability.
| Traditional EV Battery Assembly | EV Battery Assembly with Ansomat |
| Paper-based work instructions | Interactive digital work instructions |
| Manual process verification | Real-time process validation |
| Operator-dependent assembly | Step-by-step operator guidance |
| Manual torque verification | Smart torque tools with automatic validation |
| Manual component checks | Machine vision-assisted verification |
| Limited process traceability | Complete digital traceability with MES integration |
| Separate production systems | Connected manufacturing platform |
| Manual data collection | Automatic production data capture |
| Complex operator training | Guided workflows that reduce training time |
| Reactive quality inspections | Built-in quality throughout the assembly process |
By combining operator guidance, digital work instructions, and intelligent validation systems, Ansomat delivered a fully controlled EV battery assembly environment that:
✅ Ensures 100% process compliance
✅ Improves operator safety in high-voltage assembly
✅ Reduces errors and rework
✅ Enables scalable EV battery production
✅ Supports output targets of up to 30 BEV trucks per shift
Part of a Bigger Vision
This project forms part of a wider transformation at Leyland Trucks, where Ansomat supplied multiple operator guidance smart benches, embedding digital work instructions into advanced manufacturing processes.
Through collaboration with Expert Technologies Group, we delivered a future-ready solution, scalable, intelligent, and aligned with the demands of zero-emission transport manufacturing.
At Ansomat, we specialise in operator guidance solutions, combining digital work instructions with flexible, hardware-agnostic systems tailored to any assembly environment.
Our approach includes:
Delivering solutions that guarantee quality, traceability, and performance at scale.
From operator guidance software and digital work instructions to machine vision, MES integration, and error-proof assembly, Ansomat delivers intelligent manufacturing solutions trusted by leading global manufacturers.
