Automating the Unautomated: Inside �鶹��ý Automation’s��Tier 1 Automotive Manufacturer�������ڳٲ����ٱ���Assembly Cell��

When a Tier 1 automotive supplier approached �鶹��ý Automation, the goal wasn’t simply faster production—it was something far more ambitious: to fully automate a liftgate assembly process that had never been automated before, and to do it with a robotic system flexible enough to outlive the program it was built for.

Reimagining a Fully Manual Process

The existing liftgate assembly line relied heavily on manual labour, with up to twelve operators handling component loading, assembly, and quality control. Seven components were assembled by hand, and production output was directly tied to headcount and human consistency—both of which naturally limit scalability and repeatability.

�鶹��ý was tasked with transforming this entire workflow into a fully automated system. The targets were strict: sub-14-second cycle time, the ability to handle left- and right-hand variants across two models, a compact footprint, and a tight delivery timeline.

But the most important requirement shaped everything else: the customer didn’t want fixed automation. They wanted robots—reusable, reprogrammable assets that could be redeployed long after the current vehicle programs ended.

Engineering a 12-Robot System

To meet these demands, �鶹��ý designed a highly integrated cell using twelve FANUC robots, each assigned a specific role within the assembly sequence.

• Compact high-precision robots handled small components such as bushings, rings, and pins with consistent accuracy.
• Mid-sized industrial robots performed heavier loading, orientation, and transfer tasks between stations.
• Large multi-purpose robots managed complex operations including part-to-part transfers, inspection sequencing, torque testing, vision verification, and final packaging.

One of the most advanced functions was the packaging system, where finished parts were placed dynamically into shipping bins without fixed locating features—allowing flexibility across part variations.

Solving the Tolerance Stack-Up Challenge

One of the most complex engineering problems came from cumulative manufacturing tolerances. While each individual component stayed within spec, combining four parts—each at the edge of their tolerance range—created unpredictable variation that traditional automation struggles to handle.

�鶹��ý had to design tooling capable of absorbing these extremes while still maintaining speed, accuracy, and repeatability. This became one of the defining mechanical challenges of the entire project.

The Delicate Conductivity Ring Problem

A particularly difficult issue arose with ultra-thin conductivity rings that could easily deform during handling. Minor inconsistencies caused them to shingle together or misfeed in the system.

�鶹��ý solved this through a combination of mechanical redesign and controls adjustments:

• A precision adjustable gripper stop ensured consistent compression during pick-and-place.
• Conveyor timing was modified to eliminate vibration during pickup.
• A magnet system was added to ensure parts consistently settled into the same position before robotic pickup.

Together, these changes stabilized what was originally an unreliable feeding station.

Integrating a Fully Connected Control System

The control architecture tied together robots, servo presses, riveters, torque testers, vision systems, and packaging—all coordinated through a single PLC-based system.

The challenge wasn’t just making each system work, but ensuring they all worked together seamlessly within a sub-14-second cycle. Synchronization and communication across all devices were critical, with zero tolerance for sequencing errors.

Delivered Under Pressure

Midway through the project, the timeline was pulled forward by eight weeks, requiring �鶹��ý to complete integration and commissioning directly at the customer’s facility instead of in-house.

Despite the added pressure, the team resolved real-world production issues on-site, refining tolerances and stabilizing the system under live conditions until it ran reliably.

Results That Exceeded Expectations

Today, the system is fully operational and exceeds its original performance target, producing over 1.42 million liftgate assemblies annually.

What once required up to twelve operators now requires just one person to load raw components, with the rest of the process fully automated.

The robotic system is also already being considered for further evolution—potentially removing the final manual touchpoint to achieve fully lights-out production.

A New Standard for Robotic Manufacturing

This project demonstrates what’s possible when robotics, mechanical design, and controls engineering are fully integrated from the ground up. �鶹��ý didn’t just automate a process—they engineered a flexible manufacturing platform designed for long-term adaptability.

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Want to see the full technical breakdown?

Explore the complete case study here:

Tier 1 Automotive Manufacturer��Case Study

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About �鶹��ý Automation:

�鶹��ý Automation is an automation systems builder and robot integrator based in Brantford, Ontario. The company has been building custom machines, robotic welding automation and material handling systems since 2018. �鶹��ý automation serves automotive, consumer, and industrial markets across North America.

Company contact: Richard Arts, Director of Sales & Marketing | Richard.Arts@ethosautomation.com

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PRESS RELEASE | ETHOS Automation Globe and Mail Top Growth 2023

Brantford, Ontario

�鶹��ý Automation Ranks #60 on The Globe and Mail’s Top Growing Companies for 2023!

�鶹��ý Automation is pleased to announce it placed No. 60 on the 2023 Report on Business ranking of Canada’s Top Growing Companies.

Canada’s Top Growing Companies ranks Canadian companies on three-year revenue growth. �鶹��ý earned its spot with three-year growth of 675%.

“We’re thrilled to share that �鶹��ý Automation has been recognized as one of Canada’s top growing companies by The Globe and Mail, securing the impressive #60 spot on the prestigious list for 2023,” says co-founder Peter Botros. “This achievement is a testament to the relentless dedication, tireless efforts, and unwavering commitment of our exceptional �鶹��ý family. Our growth wouldn’t have been possible without the trust ofour valued clients, and the support of our partners. We are immensely grateful for your continued belief in �鶹��ý Automation.”

Canada’s Top Growing Companies is an editorial ranking that was launched in 2019. Itaims to bring the accomplishments of innovative businesses in Canada to the forefront.In order to qualify for this voluntary program; companies had to complete an in-depth application process and fulfill requirements. In total, 425 companies earned a spot on this year’s ranking.

The full list of 2023 winners along with editorial coverage is published in the October issue of Report on Business magazine. The list is out now and online

“Canada’s Top Growing Companies acknowledges the drive and ingenuity displayed by Canadian business,” says Dawn Calleja, Editor of Report on Business magazine. “This year’s ranking serves as an inspiration for future business owners.”

“This year’s Report on Business magazine’s list of Top Growing Companies shows how innovative ideas always rise to the top, perhaps even more so in times of uncertainty,”says Andrew Saunders, CEO of The Globe and Mail. “The Globe and Mail congratulates this year’s winners for meeting and surpassing those economic challenges.”

About The Globe and Mail

The Globe and Mail is Canada’s foremost news media company, leading the national discussion and causing policy change through brave and independent journalism since1844. With our award-winning coverage of business, politics and national affairs, The Globe and Mail newspaper reaches 6.3 million readers every week in our print or digital formats, and Report on Business magazine reaches 2.8 million readers in print and digital every issue. Our investment in innovative data science means that as the world continues to change, so does The Globe. The Globe and Mail is owned by Woodbridge,the investment arm of the Thomson family.

About �鶹��ý Automation:

�鶹��ý Automation is an automation systems builder and robot integrator based in Brantford, Ontario. The company has been building custom machines, robotic welding automation and material handling systems since 2018. �鶹��ý automation serves automotive, consumer, and industrial markets across North America.

Our new address:

�鶹��ý Automation Inc. 70 Easton Road Brantford, ON N3P 1J5

-30-

Company contact: Jeff Werner, General Manager | Jeff.Werner@ethosautomation.com

Sales contact: Tyler Conron | Tyler.Conron@ethosautomation.com | 905-746-9397

Press contact: Jim Beretta | Customer Attraction |  jim@customerattraction.com

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PRESS RELEASE | ETHOS Automation Announces Facility Move

Brantford, Ontario

We are excited to announce that �鶹��ý Automation has secured a 36,000 square foot facility at 70 Easton Road in Brantford. “This new home is exactly what we have been searching for”, says Jeff Werner, General Manager of �鶹��ý Automation.

“This move will allow us to support our existing client base and accommodate growth in our automation systems design and build contract work, allowing us to build larger automation systems out of one single facility”, according to Werner. 

“Moving to this state-of-the-art facility will attract the talent we need as we continue to grow the complexity and size of our customer automation systems. Giving our talented team a new, fresh consolidated workspace with dedicated areas for quality and applications will also make us more competitive”.

The consolidation and move will happen in coming weeks and we expect to be completed by the end of August 2023.

About �鶹��ý Automation:

�鶹��ý Automation is an automation systems builder and robot integrator based in Brantford, Ontario. The company has been building custom machines, robotic welding automation and material handling systems since 2018. �鶹��ý automation serves automotive, consumer, and industrial markets across North America.

Our new address:

�鶹��ý Automation Inc.

70 Easton Road

Brantford, ON

N3P 1J5

-30-

Company contact: Jeff Werner, General Manager | Jeff.Werner@ethosautomation.com

Sales contact: Tyler Conron | Tyler.Conron@ethosautomation.com | 905-746-9397

Press contact: Jim Beretta | Customer Attraction |  jim@customerattraction.com

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Whether you’re automating an assembly, inspection, welding or other process that involves positioning an item, you’ll likely either use or consider using a dial table/rotary indexer. 

A dial table is a rotary positioning device that’s often used in automation processes to maximize precision, repeatability, and throughput while minimizing the required footprint. Rotary-type positioners have many forms and names, including the following:

• assembly dials
• precision indexers
• rotary indexers 
• dial-based automation

Although a dial table may seem low tech, don’t let the simplicity fool you. These positioners are workhorses in automation systems. Dial tables are essential for achieving the results needed for many automation functions that would be less efficient using a linear positioning process. 

Rotary indexers are used for a wide range of applications including material handling, welding, dispensing, vision inspection, labeling, and pick and place. Inspection, testing, measurement, and marking are ideal for dial-based automation. 

Precision indexing 

Indexing, or starting and stopping at exact intervals is critical for precision. Rotary indexers can be extremely precise, with positioning that is accurate within microns. Small parts assembly, inspection, and labeling are often ideal candidates for automation with a dial table. Medical and pharmaceutical devices, electronics components and other small parts produced in high volume benefit greatly from precision indexing. However, dial tables are extremely versatile, and have many uses beyond small parts.  

Design flexibility with dial-based automation

Dial indexers are available in a wide range of sizes and can be customized to suit an impressive range of applications and specifications, giving machine builders excellent flexibility in design. Rotary-type indexers can be as small or large as needed. Indexers that have a large open center can accommodate a machine in the middle, such as a robot. Applications such as welding, riveting, and painting use rotary indexers that can accommodate larger parts; however, they can’t be as precise or start and stop as quickly as indexers used for smaller, lighter parts.

The need for speed.

One of the advantages of using dials, especially in automated robotic welding is that is keeps the worker safe, but allows him or her to do other tasks when the part is loaded as a trunnion and often decreasing cycle time.

Longevity of dial tables

Another key reason why so many rotary indexers are used in automation is that they are extremely low maintenance, even described as maintenance-free by many vendors. Rotary indexers are rarely the cause of automation downtime. 

As with all machinery in a specific environment, rotary indexers need to be able to withstand any harsh environments. Exposure to chemicals used in a clean room or food preparation area, salt air that could cause rust, and abrasive dust or fine particles need to be considered and planned for when specifying a rotary dial. Different vendors can provide coatings, plating, and sealing methods to protect indexers from preventable wear and tear. 

Pairing dial tables with robots

Rotary indexing is so accurate, fast, and efficient, that it has kept up with technology advancements, and is easily incorporated into robotic operations. Whether robots are feeding and removing parts from the rotary indexers, or the indexers are placing parts in front of the robot for a specific operation, rotary indexers and robots complement each other perfectly in versatile automation designs.

At �鶹��ý we are experts at automation robotics and welding automation for automotive Tier 1 and other industries. If you would like to learn more about how we can help you implement automation, contact us:

info@ethosautomation.com or

The post In praise of an Automation Workhorse: The Dial Table first appeared on �鶹��ý Automation.

“Talking Industrial Automation with Alessia”

For podcast #87, Jim invited our own Alessia Alfieri, Project manager at �鶹��ý to record a podcast. She has worked in Tier 1 Automotive industry where she met her now new boss, Peter Botros.

Here are Jim’s notes: Alessia, welcome to the podcast, thanks for joining us.

Was there an influence in your life that led you to engineering? Were you just good at all the STEM subjects?
Did your co-op experiences help you define your interests more clearly or help you figure out what you DIDN’T want to do?
So how does being a Project Manager differ from other engineering jobs you’ve held in past?
As a woman in male-dominated profession and workplace, can you talk about some of the challenges you may have had?
What advice would you have for young women considering entering engineering? Manufacturing?
What about ETHOS made you want to work there?

When you are not managing, building and deploying automation, what do you like to do?

How can people get a hold of you?

Have a listen at:

At �鶹��ý we are experts at automation robotics and welding automation for automotive Tier 1 and other industries. If you would like to learn more about how we can help you implement automation, contact us:

info@ethosautomation.com or

The post Alessia Alefieri on The Robot Industry Podcast first appeared on �鶹��ý Automation.

Building Industrial Automation Systems

According to Jim Beretta: “There is a lot going on at �鶹��ý, for such a young automation company. Calvin Kimura and his business partner, Peter Botros were named winners in Manufacturing Automation’s Top 10 Under 40 program and are setting the bar for young professionals across the industry in automated manufacturing.”

“Calvin also recently was a guest on a webinar with Manufacturing Automation magazine’s editor Sukanya Ray Ghosh on the Future of Automation Virtual Event 2022.”

Here are some of the questions that were discussed on Jim’s podcast #83:

Can you describe the types of automation that you are building?
Are there any specific tools or technologies that you are seeing now, that maybe you weren’t a few years ago?
Machine vision?
What kind of trends are you seeing in automation for welding?
Are parts getting bigger or smaller?
Are projects getting simpler or more complex?
What about industry 4.0 and maybe iiot in the machines that you are building?
A question about robots, etc. Bigger, more of them, etc.
Do customers need more help, more training?

Have a listen at:

At �鶹��ý we are experts at automation robotics and welding automation for automotive Tier 1 and other industries. If you would like to learn more about how we can help you implement automation, contact us:

info@ethosautomation.com or

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�鶹��ý uses Tecnomatix to deliver turnkey automation solutions to customers

Once we decided to offer simulation as an option for our customers, we began looking into various types of simulation software. We tried outsourcing this simulation to a third party, but that came with its own unique challenges. �鶹��ý realized they they spent a lot of time going back and forth with the supplier, so we decided to do the simulation in-house.

You can catch the total conversation and Siemens story here:

At �鶹��ý we are experts at automation robotics and welding automation for automotive Tier 1 and other industries. If you would like to learn more about how we can help you implement automation, contact us:

info@ethosautomation.com or

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When automating with a robot, the number of axes or degrees of freedom on the robotic arm determine how it can move and impact how much space it will require. Typically, up to 6 axes can be accommodated on a robotic arm, which is bolted to the floor, ceiling or mounted on a base. Adding a 7th axis or a track allows the robot to also move linearly – either horizontally or vertically. Track-mounted robots offer multiple benefits. including adding extra reach, minimizing costs, saving space, increasing flexibility and possibly saving the cost of an extra robot.

Adding extra reach to a robot arm with track mounting
A linear track can give a robot extra reach that would typically require a longer arm and more expensive robot. This extra reach is particularly useful for pick-and-place applications, machine tending, and even welding, painting, and other tasks. By optimizing reach using a track, the robot will be less bulky and take up less space than if it had a longer arm.

Maximizing the use of each robot
With a track system, one robot can move down the production line or to another location to perform additional operations. Using the same robot at multiple stations reduces the number of robotic arms needed and speeds up the payback of the robot doing this double duty. Moving one robot along a track is often significantly more efficient than using multiple units to perform each task. A track-mounted robot can also be designed to move at high speed for high productivity and throughput, and shorter cycle times. By using fewer units, minimizing floor space, and increasing efficiency, automation solutions designed with robots on tracks can significantly reduce costs.

Saving space with inverted rails
Inverted rails or gantry systems are an excellent example of the benefits of redesigning a work cell to take full advantage of robotic automation. Inverted rails can be used to suspend robotic arms so the base is above the end effector that performs the work. With the robotic arms held up by the rail mounting system, an inverted design can save significant floor space. Overhead rails are particularly useful for loading/unloading and palletizing operations. Inverted robotic arms can stack items higher more efficiently than a floor-mounted design. An inverted robot can also reach high places that would present a safety hazard for humans to access.

Increasing versatility and flexibility of the robotic solution design
Since a track system takes up less space and can reduce the reach required on the robotic arm itself, there will be fewer design constraints on the overall system. Also, tracks can be set up with a variety of mounting orientations, allowing even greater flexibility to optimize space and efficiency. For example, angle mounting can be used for precise positioning, and to accommodate custom requirements.

Integrating track-mounted robots into an automation plan
The optimal way to design a track-mounted system will depend on the operations being performed, floor space available, safety concerns, and many additional factors. Independent manufacturers specialize in linear axes, providing modular components that can be combined with automation solutions. Many of the major robot manufacturers have rail-mounted robots.

As for negatives, it takes more upfront engineering work to calculate the size, payloads and constraings. But other then that, 7th axis is always a positive

At �鶹��ý we are experts at automated welding automation for automotive Tier 1 and other industries. If you would like to learn more about implementing track-mounted robots, contact us at

info@ethosautomation.com or

The post Robots and Automation What is a 7th Axis? first appeared on �鶹��ý Automation.

Many factors play into the decision to automate certain welding tasks, and scarcity of manual welders is one of them. According to provided by the American Welding Society, on average, 84,000 welding jobs are expected to be filled annually between 2022–2025. However, more than 150,000 welders are approaching retirement. Automated welding robots are not a direct replacement for experienced welders; you don’t simply replace a person with a robot. However, there are certain welding tasks that can be done extremely efficiently through automated robotic welding.

Strategic automation allows you to conserve scare human resources for custom jobs and creative problem solving. It’s also possible to implement collaborative solutions where a welder uses a robot as an extra set of hands. For example, offers collaborative arc welding robots such as the CRX.  While collaborative robots have safety features incorporated that accommodate safe operation in proximity to a human, it’s essential to carefully design the overall robotic welding cell to ensure safety.

Determining when it makes sense to use automated robotic welding

As with any automation project, it’s essential to consider multiple factors to determine when a robotic solution makes sense. 

Requirements. A wide range of robot arms can be used to wield a welding tool.Standard robotic solution requirements such as reach, payload, and footprint will help narrow down options to determine if a robotic solution will work and which suppliers can meet the specifications.

Volume plays a big role in return on investment. Medium-high volume, low-medium mix processes are often good contenders for automated solutions.

Repeatability. When the same weld needs to be done on the same parts exactly the same way, robotic solutions can be ideal. A programmed robot can deliver an extremely high degree of repeatability and compliance with Weld Procedure Specifications. The correct parameters can be programmed into the robot to ensure that they’re done consistently. 

Parts presentation. To take advantage of the efficiency potential of a robotic solution, the parts that the robot needs to pick up and put down should be able to be presented in a programmable fashion such as rows. It is possible to pick up disorganized parts, but generally presentation trays or other orderly means of working with the robot should be found.

Benefits of robotic welding

In addition to filling a resource gap, there are many benefits of automating welding with robotic solutions.

Accuracy. For welds that require a high degree of accuracy and precision, robotic solutions can be extremely advantageous. When welding tasks necessitate accuracy, lower volumes can often be handled with better efficiency and lower rework with robotic solutions.

Repeatability. Robotic solutions excel at repeatability. The more repeatability involved in a process, the higher likelihood that a robotic solution will quickly show its worth.

Safety. Dull, dirty and dangerous jobs are often best left to robots. If a weld must be done in an atmosphere that’s potentially hazardous to humans, a robot can be the best solution even for low volume production.

Quality. Once a robotic solution has been designed, implemented and successfully tested, the quality of work will remain consistently high. Any factors that could cause a quality issue can be automatically monitored and flagged so that downtime and rework are minimized. To learn more about the benefits and feasibility of robotic welding solutions, contact

info@ethosautomation.com or

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