Robotic Applications
We engineer robotic cells that hit cycle time on day one. Brand-independent integration, in-house mechanical and electrical teams, commissioning guarantee.
BIOS delivers Industry 4.0-scale robotic projects end-to-end: mechanical design, manufacturing, electrical engineering, PLC and HMI software, robot programming, and commissioning — all under one roof, all in-house.
We proved that capacity on the TOFAŞ–ABB K0 project: 13 months, 103 robots, 40 fixtures, 15 conveyors torn down and rebuilt, and PLC software rewritten to the customer's standard. Greenfield install, modernization, or brand changeover — we deliver each the same way. With a commissioning guarantee.
• Custom by default. Every cell is engineered around your part, not pulled from a catalog.
• Brand-independent. ABB, FANUC, KUKA, Yaskawa, Universal Robots — selected to fit your application.
• One contract, one team. Mechanical, electrical, PLC, robot programming, safety — all in-house.
• Commissioning guarantee. We stay on site until the line runs at target cycle time.
Six core service categories across a range of applications — from robotic cell design through to commissioning.
Robotic Welding Cells
MIG, MAG, TIG, and spot welding cells — from high-volume automotive body lines to low-volume precision welding. Built around the part geometry, cycle time, and weld quality your line demands.
Automated Assembly
Multi-part automated assembly: screwdriving, press-fitting, clip insertion, and component placement. Built for automotive, electronics, and home appliance production lines.
High-Speed Pick & Place
High-speed pick-and-place systems for sorting, kitting, and transfer tasks. Delta, SCARA, and 6-axis configurations selected to match precision and throughput requirements.
Palletizing and Depalletizing
End-of-line palletizing and depalletizing robots for cases, sacks, and bagged products. Programmable pallet patterns and conveyor integration with stretch-wrapping systems.
Spray Painting and Coating
Spray painting robots for uniform coating across complex 3D surfaces. Consistent film thickness, reduced material waste, and operators kept clear of hazardous chemical environments.
Vision-Guided Robotics
Camera-integrated robot systems for part recognition, in-line quality control, and adaptive positioning. High repeatability even with variable part positioning.
Industries We Build For
Robotic solutions from automotive body lines and home appliance assembly to heavy metal processing and precision food packaging.
Automotive
Body welding lines, press shops, paint lines, assembly cells, and supplier plants. OEM and Tier-1.
Energy
Turbines, generators, transformers, switchgear, maintenance lines, and industrial control systems.
Home Appliances
Refrigerator, washing machine, oven, and air conditioner production lines; press, assembly, test stations, packaging, and end-of-line systems.
Defense Industry
Precision machining workshops, test and calibration facilities, restricted-access production lines, and assembly cells.
Chemicals
Reactors, mixers, filling and packaging lines, storage tanks, and process control infrastructure.
Food
Filling, packaging, and palletizing lines, sterilization units, confectionery and chocolate plants, and cold storage.
Metal & Mining
Rolling mill equipment, foundries, welding and cutting lines, heavy-tonnage presses, and end-of-line automation.
Paper & Packaging
Printing machinery, sheeting and cutting lines, palletizers, corrugated and flexible packaging plants.
The same five-step process on every project — from feasibility study to commissioning.
Line Analysis and Feasibility
Our engineers visit the site to assess cycle times, footprint constraints, part geometry, and throughput targets. We identify the automation opportunities with the highest ROI and deliver a detailed feasibility report with payback estimates.
Robot Selection and Cell Design
The optimal robot brand and model are chosen for the application — brand-independent, always in the project's interest. Cell layout, gripper, and tooling design are validated through 3D simulation. No hardware is ordered until your technical team has signed off on the design.
System Integration and Programming
Mechanical installation, electrical wiring, PLC and robot programming, safety guarding, and sensor integration are all handled by our in-house teams. Critical engineering work is never handed off to subcontractors.
Testing and Validation
Dry-run testing, cycle-time verification, and quality checks are completed in our workshop or on site before the system goes live. All performance data is documented against acceptance criteria and submitted for customer approval.
Commissioning, Training, and Handover
Production start-up is managed on site by our engineers. Operator and maintenance training is delivered under real production conditions. Full handover documentation — programs, electrical drawings, spare parts list, and user manuals — is provided in the requested language.
28-Robot Door Line — Yeniköy Body Plant
Door welding line teardown, rebuild, robot teaching, and full automation at the Yeniköy body plant. Design, manufacturing, mechanical, electrical, and automation scope — delivered end-to-end.
B460 Door Lines — Relocation and Tie-In
14 robots moved from the left side to the right, enabling both left- and right-hand door production on the same line. Mechanical design, E-Plan revision, panel revision, PLC/HMI software, robot programming, and commissioning.
K0 Underbody — Teardown, Install, and PLC Programming
After Doblo production wrapped up, the existing robot lines and fixtures were torn down, the K0 line was rebuilt to the new layout, and the automation panels and PLC software were rewritten to TOFAŞ standards. A 13-month full-scope project.
Windshield Washer Fluid Filling Station — Turnkey
Design and integration of an automated washer fluid filling system for the new Hybrid C-HR, using sensors and PLC-controlled pumps. Capability to fill at different positions for a second model and return to home position after each cycle. Mechanical design, manufacturing, PLC software, and commissioning.
The end-to-end process of automating a production line — or specific stations within it — with industrial robots. The right call for high-volume, repetitive, ergonomically tough, or high-precision work. Welding, assembly, pick-and-place, palletizing, spray painting, vision-guided quality — all shorter cycle time, more consistent output, and operators out of harm's way.
Both depend on your line. Cost is driven by robot count, payload, reach, end-of-arm tooling, safety scope, PLC and software hours, and site infrastructure. Payback depends on shift count, current labor cost, scrap rate, rework cost, and cycle-time gain. After our feasibility study, you get a detailed report with investment cost and estimated payback. Typical automotive and home appliance payback runs 12-36 months — calculated for your site.
We're brand-independent. We deliver projects with all major industrial robot brands, plus Universal Robots. Selection comes out of the feasibility study, based on application, target cycle time, payload, reach, and your site standards. No brand is committed up front.
Yes. Robots integrate with existing PLCs over Profinet, EtherNet/IP, Profibus, EtherCAT, and OPC UA. If your standard requires it, we rewrite the PLC and HMI software — exactly what we did on the K0 project, building the PLC software from scratch to TOFAŞ standards. Real-time data exchange with SCADA, MES, and ERP is fully supported.
All cells are CE-marked and built to EN ISO 10218 (industrial robot safety), EN 60204-1 (machinery electrical equipment safety), and EN ISO 13849 (control system safety). Risk analysis, laser scanners, safety light curtains, and category-rated emergency stop circuits are included. We hold ISO 9001:2015 and OHSAS 18001 certifications.
Automotive (OEM and Tier-1), home appliances, defense, food, chemicals, energy, metal and mining, paper and packaging. The deepest reference base is automotive — Ford Otosan, TOFAŞ, Toyota, BMC. Welding lines, body plant modernizations, assembly cells, filling stations.
Single-cell pick-and-place or palletizing: 2-4 months. Multi-robot welding lines and body plant modernizations: 6-13 months. Real numbers: the TOFAŞ-ABB K0 project — 103 robots, 40 fixtures, 15 conveyors — torn down, rebuilt, and commissioned in 13 months. The Ford Otosan B460 project — 14 robots repositioned — 6 months.
Both work. Repositioning existing robots, adding new ones, updating PLC software, and revising electrical panels usually delivers faster payback. Brand changeovers — swapping older robots for newer models — are in scope too. On the Ford Otosan B460 project, we repositioned the existing 14 robots so the same line could run both left- and right-hand doors.
Industrial robot: high speed, heavy payload, long reach, fenced cell. Cobot: built-in force sensors, works alongside operators, no physical barrier. High-volume welding, palletizing, and press work → industrial robot. Low-volume, high-mix production and operator-assist tasks → cobot. Both are in our portfolio.
MIG, MAG, TIG arc welding, and spot welding. Stud gun (stud welding) is in scope too. The cell ships as a single package: welding machine, wire feed, gripper and fixture integration, fume extraction, laser-scanned safety light curtains, and operator panel.
Yes. Operator and maintenance training under real production conditions after commissioning. Full handover documentation — robot programs, electrical drawings, spare parts list, user manuals — in the requested language. 24/7 on-site and remote support post-commissioning, and preventive maintenance contracts that keep your robots at target cycle time.
Talk to Our Engineers
Send us the brief. We'll come back within 24 hours.
Ready to Bring Robots to Your Line?
Greenfield install or modernization — talk to our engineers for a no-commitment assessment. Real timelines, real costs, built around your process.