Custom Automated Production Lines

From concept to commissioning — Keli Automation designs and builds custom automated production and assembly lines tailored to your unique product and process requirements. With 30+ years of non-standard automation experience, we deliver turnkey solutions that improve quality, increase throughput, and reduce labor dependency.

Types of Automation Lines We Build

Comprehensive automation solutions covering the full product lifecycle from assembly through packaging.

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Automated Assembly Lines

Full or semi-automatic assembly lines integrating feeding, joining, screwing, pressing, and fastening processes. Designed around your product assembly sequence with modular stations for flexibility and future product changes.

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Automated Test Lines

Dedicated test automation lines for functional testing, performance validation, and quality verification. Integrates ICT, FCT, vision inspection, leak testing, and other test methods with automatic pass/fail sorting.

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Burn-In & Aging Lines

Temperature-controlled aging and burn-in lines for reliability testing of electronics, power supplies, and battery products. Programmable thermal profiles with continuous data logging and automatic fault detection.

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Automated Packaging Lines

End-of-line packaging automation including cartoning, labeling, sealing, and palletizing. Integrates with upstream production for seamless product flow and supports multiple packaging formats with quick changeover.

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Loading & Unloading Systems

Automated material handling systems for machine tending, conveyor transfer, and in-process buffer storage. Includes robotic machine tending, tray handling, and flexible feeding solutions.

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Visual Inspection Systems

Machine vision-based inspection solutions for defect detection, measurement, verification, and sorting. Uses AI-enhanced image processing for consistent quality control beyond human inspection capability.

Our Core Engineering Capabilities

An in-house multidisciplinary team handles every aspect of your automation project from concept to production.

01

Line Design

Complete production line layout, process flow design, cycle time analysis, and factory integration planning.

02

Mechanical Design

Precision mechanical engineering using SolidWorks — structural design, mechanism design, and custom tooling.

03

Electrical Control

PLC programming, motion control, sensor integration, safety circuits, and electrical cabinet design & assembly.

04

Software Development

HMI design, data collection systems, vision algorithm development, and MES/ERP system integration.

05

System Integration

Multi-station line integration, robot integration, vision system integration, and conveyor & material handling.

06

Debug & Delivery

Factory acceptance testing, on-site installation, commissioning, operator training, and SAT support.

Industry Applications

Industry-specific automation expertise built over 30+ years of serving manufacturing leaders.

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3C Electronics

Smartphones, wearables, chargers, connectors

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Automotive Parts

Sensors, actuators, electronic components

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New Energy

Battery modules, solar inverters, EV components

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Medical Devices

Diagnostic equipment, consumables, implants

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Home Appliances

Motors, controllers, small appliance assembly

Our Customization Process

An 8-step project delivery methodology refined over hundreds of successful automation projects.

1

Requirement Study

On-site visit, process analysis

2

Concept Design

Scheme proposal, budget estimate

3

Detailed Design

3D modeling, BOM, drawings

4

Manufacturing

Machining, procurement, assembly

5

Assembly & Debug

Factory integration, FAT testing

6

On-Site Acceptance

Installation, SAT, production trial

7

Training & Delivery

Operator training, documentation

8

After-Sales

Warranty, maintenance, upgrades

Automation Level Selection Guide

Choosing the right level of automation depends on your volume, product complexity, labor costs, and quality requirements.

Entry Level

Manual / Semi-Automatic

  • Low production volume (under 50k units/year)
  • High product mix, frequent changeovers
  • Lower initial investment
  • Operator-dependent quality
  • Flexible for product development
  • Quick deployment (4–8 weeks)
Best for: Startups, R&D, low-volume high-mix production
Mid Level

Semi-Automatic Line

  • Medium volume (50k–300k units/year)
  • Key processes automated, manual assist
  • Balanced investment & flexibility
  • Improved quality consistency
  • 30–60% labor reduction
  • Deployment in 12–20 weeks
Best for: Growing manufacturers, mature products with stable demand
High Level

Fully Automatic Line

  • High volume (300k+ units/year)
  • Minimal operator intervention
  • Higher initial investment
  • Maximum quality consistency
  • 70–95% labor reduction
  • Deployment in 20–40 weeks
Best for: Mass production, stable product design, strict quality requirements

ROI Calculation Model

Investing in automation delivers returns through multiple channels. We help you build a comprehensive ROI analysis based on your specific situation.

ROI (months) = Total Investment ÷ Monthly Savings

Key Savings Factors:

  • Labor cost reduction: replacing operators with automated stations
  • Yield improvement: fewer defects and rework from consistent processes
  • Production capacity increase: higher throughput per shift
  • Material waste reduction: precise dispensing and controlled processes
  • Quality cost reduction: fewer customer returns and warranty claims
  • Energy savings: optimized process parameters and scheduling

Our team can provide a detailed ROI analysis with your specific parameters during the quotation phase.

[自动化产线图片占位 Automation Line Image Placeholder]

ROI Analysis Dashboard

Frequently Asked Questions

Common questions about custom automated production lines.

How long does it take to build a custom automation line?
Project timelines vary significantly based on complexity. Semi-automatic stations typically take 8–16 weeks. Multi-station automated lines require 20–40 weeks from order to delivery. Very complex full production lines with multiple integrated systems may take 6–12 months. We provide a detailed project schedule with milestones during the proposal phase, and we keep you updated throughout execution.
What information do you need to provide a quote?
To give you an accurate quote, we need: product drawings/samples, assembly process description, target production rate (pieces per hour/day), current process photos or videos if available, factory layout constraints, quality requirements, and any specific regulations or standards. The more detail you provide, the more accurate our proposal will be. We're also happy to schedule an on-site visit for complex projects.
What is your pricing model for custom automation lines?
We offer turnkey pricing based on project scope. The quote includes design, manufacturing, assembly, testing, installation, and training. Payments are typically structured in milestones: deposit (30%), mid-term progress payment (30%), pre-shipment FAT payment (30%), and final payment after on-site acceptance (10%). For long-term partners, we can discuss flexible payment terms.
Do you provide after-sales support and warranty?
Yes. All our automation lines come with a 12-month warranty from acceptance date, covering manufacturing defects and component failures. We provide 24/7 remote technical support, and for issues that can't be resolved remotely, we dispatch engineers on-site. We also offer optional annual maintenance contracts for ongoing support, preventive maintenance, and software updates.
Can you modify an existing production line or integrate new stations?
Absolutely. Many of our projects involve upgrading or extending existing production lines rather than building from scratch. We can add new stations, integrate robotic automation, upgrade controls, add vision inspection, or improve cycle times on existing equipment. We'll assess your current line and propose the most cost-effective upgrade path.
What if our product design changes after the line is built?
We design our lines with modularity in mind to accommodate product changes. Depending on the scope of the change, we can modify tooling, add changeover kits, adjust programming, or add new stations. During the design phase, we always consider future product variants and plan for flexibility where appropriate. Modification costs are typically much lower than building a new line from scratch.
What safety standards do your automation lines follow?
Our automation lines are designed with safety as a top priority. We follow international standards including ISO 13849 for safety-related control systems, ISO 10218 for industrial robots, CE marking requirements for European customers, and OSHA guidelines. Each system includes safety features such as light curtains, safety interlocks, emergency stops, and guarded access points. We provide full risk assessment documentation.
Do you support international installation and service?
Yes, we serve customers worldwide. Our engineers regularly travel to customer sites for installation, commissioning, and training. For international projects, we handle all export documentation and logistics. We also have service partners in several regions for faster local support. Remote diagnostic capabilities are built into all our systems, allowing us to troubleshoot most issues without on-site visits.

Explore related solutions: SMT Production Lines | Robotic Solutions | Fixtures & Tooling

Learn more: [Blog: ROI Calculation Guide for Automation Projects]

Have a Custom Automation Project?

Tell us about your production challenges. Our engineering team will analyze your requirements and propose a tailored automation solution with ROI estimation.

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