The Challenge

EV battery assembly at VDL Nedcar was impacted by:

Paper-based work instructions that were difficult to follow and prone to error
A lack of clear visual guidance on where to pick parts from across two kitting carts and the main assembly station
High product variability driven by multiple EV battery OEMs, increasing complexity and the risk of mistakes

The result was a process that relied heavily on operator skill and experience, making consistency difficult to guarantee.

Testing the Impact of Operator Guidance

In collaboration with TNO, VDL Nedcar conducted controlled experiments to evaluate whether operator skill level influenced assembly quality when using Ansomat Digital Guidance.

Two groups, including students with little to no manufacturing experience,were asked to perform identical EV battery assembly procedures. Despite the difference in background, both groups achieved:

Consistently high performance
Minimal errors
Strong adherence to the defined process

This proved that Ansomat’s operator guidance system removes variability caused by differing skill levels and enables anyone to perform complex assembly tasks accurately by following structured, step-by-step instructions.

Overcoming the Challenge with Ansomat Operator Guidance Solution

Picking & Assembly Guidance Through One Integrated System

Ansomat delivered a turnkey operator guidance solution that controls, verifies, and visually guides every step of the EV battery assembly process.

How It Works

Projector & 3D Sensor on Each Kitting Cart
Every kitting cart is equipped with a projector and 3D sensor that visually highlights the exact bin from which the operator must pick the correct component.

Dynamic Work Instructions at the Assembly Station
Instructions automatically adapt to the specific battery or product variant being built, eliminating confusion across multiple OEM configurations.

Vision-Based Action Validation
A vision system confirms that every operator action is completed correctly before allowing the process to continue.

Projected Assembly Steps on the Work Surface
Assembly steps are projected directly onto the workstation, guiding the operator in real time.

Integrated Picking & Assembly Software
Picking from multiple carts and assembly at the main station are all controlled within the same software platform, ensuring full consistency and traceability.

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The Result

VDL Nedcar now operates a highly flexible, scalable, and error-proof manual EV battery assembly process. Operators, regardless of experience, can execute complex tasks reliably, while management gains full visibility into every step of the build.