Scaling 484 Robots in a Live Factory: The Chery Dalian Blueprint

The Dalian project represents a significant shift in how automotive manufacturers approach modernization. While greenfield facilities allow for automation to be baked into the blueprints, brownfield sites present a chaotic landscape of fixed layouts, legacy IT infrastructure, and constant human traffic. Operating within this environment, the ForwardX system manages 127 distinct material categories across the bodyshop and final assembly lines.

In the bodyshop, 204 robots handle 80% of material demand, while 280 units in final assembly cover 90% of logistics requirements for an output of roughly 1,000 vehicles per day. Success in these active zones relies on vision-based autonomy and sophisticated fleet orchestration that weaves robot paths through existing conveyors and manual workstations. According to Nicolas Chee, founder and CEO of ForwardX Robotics, the project proves that the true test of automation lies not in the machinery itself, but in the ability to integrate into established manufacturing workflows without interrupting the flow of goods.

By prioritizing phased implementation over structural reconstruction, the deployment demonstrates a scalable model for Tier 1 suppliers and OEMs looking to upgrade aging assets. The transition highlights that the future of automotive manufacturing is not necessarily about building new, robot-ready facilities, but about retrofitting the ones that already define the industry.