Delivering Intelligent Assembly for the Next Generation of Electric Trucks

As part of the £5.1m ZETTA programme, Ansomat, working through Expert Technologies Group, played a key role in enabling scalable, high-quality EV battery production at Leyland Trucks.

Our advanced operator guidance system, powered by digital work instructions, ensures every step of the battery assembly process is controlled, validated, and fully traceable, supporting the UK’s transition to zero-emission transport.

Project Overview

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.

Our Solution

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:

Guide operators step-by-step using interactive digital work instructions
Ensure every action is completed correctly and in sequence
Standardise processes through assembly work instructions
Deliver consistent, repeatable assembly outcomes

Key Technologies & Capabilities

🔧 Intelligent Tooling & Operator Guidance Integration

2x operator guidance stations with digital work instructions
2x machine vision systems
1x RTLS (Real-Time Location System)
3x DC fastening tools per station
2x multi meter integration
Fully integrated with MES systems
Enables real-time torque control, data capture, and full traceability

📍 3D Position Control with RTLS

Ensures tools are used in the correct position in 3D space
Prevents incorrect fastening locations
Enhances accuracy within guided assembly processes

👁️ Vision System Validation

Verifies correct component placement and process execution
Works alongside operator guidance and digital work instructions
Adds an additional layer of quality assurance

🧠 MES Connectivity & Traceability

Full integration with manufacturing systems
Captures every operator action and tool result
Supports end-to-end traceability across all assembly stages

🖥️ Digital Work Instructions & Operator Guidance

Intuitive, screen-based assembly work instructions
Reduces training time and operator error
Ensures standardised processes across all users
Enables a fully guided, compliant assembly environment

The Result

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.

Why Ansomat

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: