HORSE Reveals Innovative Digital ‘Matrix Flow’ For HEV And PHEV Production

HORSE, a prominent figure in the realm of powertrain systems, has recently unveiled its innovative fully digital automated production process, dubbed Matrix Flow. This cutting-edge approach revolutionizes traditional manufacturing methods by replacing conveyor belt systems with autonomous platforms and workstations, referred to as Mobile Programmable Cobots (MPCs). These MPCs are designed to deliver precise components and sub-assemblies directly to both staff and robots, enhancing the efficiency of the production line.

The introduction of Matrix Flow marks a significant shift towards agile and responsive manufacturing. By facilitating wireless communication between MPCs, the system ensures rapid adaptation to fluctuations in parts supply and production demands. This not only boosts flexibility but also minimizes downtime, maintaining high standards of product quality and sustainability. HORSE's Aveiro plant in Portugal is set to implement this novel process for the construction of Power Electronic Boxes (PEBs) for Hybrid Electric Vehicles (HEVs) and Plug-in Hybrid Electric Vehicles (PHEVs), with an initial production target of 150,000 units annually, aiming to increase to 200,000 by the end of 2024.

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One of the most notable benefits of the Matrix Flow process is its impact on the factory's physical footprint. By adopting this new method, HORSE has successfully reduced the floor space required for its operations by 25% and the overall building size by 30%. Furthermore, energy consumption at the site has been halved, showcasing the company's commitment to environmental sustainability. The digital identification of components within this system eliminates the need for paper labels, further enhancing accuracy and reducing waste.

The Aveiro facility has been meticulously designed to support the production of high-tech electric powertrains, providing a clean and sterile environment that is crucial for maintaining product integrity. To ensure a smooth transition to this advanced manufacturing process, HORSE has invested in comprehensive training for its production staff. Utilizing virtual reality goggles and bespoke software, employees are equipped with the skills necessary to navigate the complexities of Matrix Flow efficiently.

HORSE's global presence is marked by its eight production plants spread across seven countries, alongside three R&D centers and a head office located in Madrid, Spain. With an annual output of 3.2 million units, the company is at the forefront of developing innovative power solutions that cater to the growing demand for sustainable mobility options. The Matrix Flow process not only positions HORSE as a leader in production technology but also aligns with the automotive industry's shift towards electrification, enabling quick and efficient scaling of production to meet market needs.