Driving the Future of Bus Assembly

Leading the Way in Quality and Efficiency

In an industry largely dominated by manual processes, major gains can be made through careful implementation of the right adhesive and sealant systems. Hand-welding and hand-mounting of panels are often the norm, resulting in time-consuming, labor-intensive processes along with a range of persistent quality issues. In collaboration with Sika, manufacturers have an opportunity to comprehensively evolve their assembly processes with the latest advances in automated pre-treatment and adhesive application.

A Strategic Alliance

For one of the world’s largest bus and coach manufacturers, the journey began more than a decade ago as an ambition to take a leading role in the global production of next- generation new energy vehicles. In Sika, they found not just a supplier but a strategic collaborator – a partner with the right technical expertise, responsive local presence and a team of global experts to solve some of the most challenging adhesive applications.

Continuous Innovation 

The goal was to perform a holistic overhaul of the company’s production to optimize assembly processes, elevate quality standards, enhance durability and reduce overall costs. To turn this vision into reality, Sika assembled a project team that could support the full customer journey. Researchers and developers, technical service professionals, system engineers and more all came together, forming a multidisciplinary team capable of tackling the challenges that  lay ahead.

An iterative process was established that included regular factory audits, computer simulations and continual implementation of innovative products and automated systems. An annual workshop with the Sika and customer teams became the breeding ground for ideas, resulting in numerous systems being implemented throughout the assembly process, from lamination and glass bonding to sealing and reinforcement.

This agile methodology formed the backbone of a decade- long evolution of current manufacturing processes and new automated factory facilities. It allowed the teams to proactively address emerging challenges and consistently improve the efficiency of process implementation and production.

Pushing the Limits of Quality and Automation

With Sikaflex® Booster, the customer implemented an accele rated adhesive system to ensure rapid and dependable bonding even in challenging winter temperatures. Through close development with the customers’ process engineers and automation system providers, Sika helped to implement this new adhesive in one of the world’s most advanced robotic dispensing and assembly environments. To further raise quality and efficiency standards, body shop sealants and adhesives were also implemented. This enabled overall improvements in quality, strength and durability. These examples are just a few of the continual process enhancements that were only made possible through close collaboration with dedicated teams of local Sika technical experts. The customer, now the world’s largest bus manufacturer, churns out more than 50,000 vehicles annually through its commercial vehicle division, including a substantial fleet of electric and other renewable-energy vehicles for the global export market.

The Journey Continues

Along the way, Sika and its partner have continued to chart the course toward a more sustainable and efficient future for bus manufacturing. Whether implementing next-generation automated assembly systems or incorporating emission-free adhesive materials into the production line, the journey of pioneering innovations continues. Together, we’re building the futured of advanced bus assembly systems, consistently f inding new ways to move the industry forward.

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