Case Study: Global Automotive Manufacturer achieves weekend line changeovers and 82% more flexibility with eFlex Systems' eFlex Assembly

Flexible Assembly Line vs Highly Automated Fixed Tooling

Global Automotive Manufacturer faced a critical challenge: both of its V6 engine plants needed to re-rate production and introduce new models, but one plant used a highly automated fixed-tooling line that was inflexible and time-consuming to change while the other had deployed eFlex Assembly from eFlex Systems. The fixed line required months of prep, extensive outsourced engineering and a 9‑day shutdown, creating lost opportunities and slow responses to market changes.

eFlex Systems implemented its eFlex Assembly flexible, plug‑and‑play architecture, enabling the plant to complete a full line changeover over a 2‑day weekend (about 200 man‑hours) with the line running at rate by midday Monday—versus 1,800+ man‑hours and a 9‑day shutdown for the fixed tooling line. The eFlex Systems solution delivered measurable impact: 82% greater flexibility, ~35% cost savings on new lines, 40–50% faster new‑line delivery, major‑change costs of $10k–$30k (vs $100k–$250k), and the ability to react in hours/days rather than weeks/months.