From body and press shops to paint lines and final assembly — we provide fully integrated engineering services for OEM and Tier 1 manufacturers. Working across major automotive plants in Turkey, including Ford, Tofaş, Toyota, BMC, and Otokar, our teams handle everything from greenfield line installations and capacity upgrades to robotic cell integration, fixture design and build, line decommissioning, and full recommissioning support.
Automotive manufacturing runs on zero tolerance for downtime. Every project in this industry demands precise coordination across disciplines, strict quality compliance, and the ability to absorb complexity without losing schedule. BIOS brings all of that under one roof — mechanical engineering, PLC and automation, heavy lifting, and on-site commissioning managed as a single, accountable scope. The 28-robot door line project at Ford Yeniköy, the K0 underbody work at Tofaş, and the windshield fluid filling station at Toyota speak for themselves: technically demanding, large-scale, and delivered on time.
- Body, press and paint line installation
- Robotic cell integration and fixture build
- Line decommissioning, relocation and recommissioning
- PLC programming and automation commissioning
- Electrical panel manufacturing and site installation
At Ford's Yeniköy body plant, we took full turnkey responsibility for the decommissioning, relocation, reinstallation, and commissioning of the existing door production line. Engineering, fabrication, mechanical and electrical installation, and automation commissioning were all managed under a single project structure — no handoffs, no gaps.
The scope included the repositioning and reinstallation of 103 robots, 40 fixtures, 15 conveyors, 33 grippers, 14 stud guns, and 5 arc welding stations to match the new line layout. PLC software was revised to Ford standards, and all safety systems were fully reconfigured for the new configuration.
Our team remained on-site for the full 13 months — not leaving until production hit its target rate and quality level. The customer's restart schedule was met without exception.
