The tricks of manufacturing superheroes

Looking at the Škoda car production line, you might think some workers have the strength of Marvel superheroes. They fit the large and heavy parts into place with graceful ease. But how do they do it? With the help of special tools.

10. 4. 2025 Models Elroq

Of course, working on an assembly line still requires strength, but the operators are effectively assisted by special electric and pneumatic manipulators and tools. This allows them to focus on precision and accuracy. These manipulators function as amplifiers of human strength rather than autonomous robots carrying out the work themselves. The worker’s hand guides the device, and sensors detect the pressure and direction of their movement, adjusting the mechanism accordingly.

The doors require absolutely precise fitting, which can be done by one person.

For instance, the wheel mounting manipulator is controlled by pneumatic circuits and designed to enable quick and precise wheel mounting to the hub without the risk of damaging the wheel arches. It can handle wheels ranging from 16 to 21 inches in diameter. “Wheel weights vary from 20 to 35 kilograms, depending on the model. Additionally, since the wheels are stacked on pallets, lifting the lower ones would require deep bending, placing excessive strain on the musculoskeletal system, particularly the lower back,” explains Lucie Vacková, workplace ergonomics coordinator, describing the effort saved by the manipulator.

At each workstation, an operator (who rotates with others during the shift) mounts both wheels on their side of the car. Over the course of a shift, up to 440 cars can be fitted with wheels, totalling 880 wheels. The combined weight of these wheels ranges from 20 to 25 tonnes.

The weight of the decorated door ranges between 35 and 40 kilograms.

“Legislation allows an employee to lift a total of 10 tons over an eight-hour shift,” says Lucie Vacková, emphasizing why manipulators are essential. “At Škoda Auto, manipulators are standard. They contribute to better workplace ergonomics, eliminate the risk of injuries when handling heavy parts, and increase both work safety and employee comfort,” she lists the benefits.

Once the wheels are in place, another tool comes into play, this time speeding up the process considerably. The operator uses a device that tightens all the wheel bolts simultaneously. It’s almost like peeking into a pit stop at a racing event, except this special five-arm wrench looks even more futuristic than the pneumatic guns used by Formula 1 mechanics.

The weight of one tyre is 20 to 35 kg, depending on its size.

There are many more instances in Škoda’s production where technology assists workers in handling large and heavy components. In the video, you can see how easily the entire dashboard "flows" into place or how seamlessly the doors are attached. Each of these parts is not only bulky and heavy (the dashboard weighs around 60 kg, and the fully equipped doors of the Elroq weigh between 35 and 40 kg) but also requires absolute precision in positioning.

Regardless of the part’s weight, the maximum force required to operate the manipulators is 80 N, which roughly corresponds to lifting 8 kg. “In most cases, however, the force needed is even lower,” adds Lucie Vacková. Moreover, employees always handle parts in an optimal position, significantly reducing strain on the musculoskeletal system. This means they have more energy left for activities outside of work.

The dashboard can be installed in a car by just one person, and it weighs a respectable 60 kilograms.