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Success Story

Headliner Assembly VW

The ergonomically difficult task of fitting the headlining is a good example of the benefits of sensor-guided robot applications in assembly. A 6-axis heavy-duty robot, by employing a sensor system from AI°, measures itself on the vehicle and subsequently fits the headlining into the same within optimised tolerances – with repeat accuracy despite existing tolerances in the process.

Initial Situation

Volkswagen is aiming for a high level of automation also in assembly. The challenge therefore exists, to address the strong positional variations of the vehicle in an automated assembly process. In our example, a headliner is installed, which in conventional manual assembly would involve several operatives. Such headliner has to be inserted through the front of the vehicle and subsequently pressed into the locks with one operative working in a supine position. Obviously, this is not very ergonomic.


With the help of the AI° robot position optimisation system, the actual position and orientation of the vehicle is detected. The robot, which is equipped with a component gripper, receives correction data directly from the sensor system in all degrees of freedom and installs the headliner with 100% reliability in the roof of the vehicle in question.

Client Value Proposition

Through the automation of ergonomically unfavourable workplaces, the re-deployment of employees to other, more value-adding and complex tasks, which have been proven to be difficult to automate, becomes possible.


Light section sensors AI° VISIONSCANNER2 with KUKA heavy-duty robots.


  • Cycle time 120 seconds
  • Measuring speed 200ms
  • Multiple vehicle variants possible