Heading
Close X
Menu
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.
Anyone who has ever changed a car tyre knows it’s no easy task. For example, the 21-inch Supernova alloy wheel, available for the Elroq and Enyaq electric car models, weighs over 30 kilograms (including the tyre). That’s heavier than a full bag of cement! Yet, on the production line, installing and tightening four wheels on a car takes only a few seconds.
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. The worker’s hand guides the device, and sensors detect pressure and direction, adjusting accordingly.
For instance, the wheel mounting manipulator is controlled by pneumatic circuits and designed for quick, precise wheel mounting without damaging the wheel arches. It can handle wheels from 16 to 21 inches in diameter.
“Wheel weights vary from 20 to 35 kilograms, depending on the model… lifting the lower ones would require deep bending, placing excessive strain on the musculoskeletal system,”
— Lucie Vacková, workplace ergonomics coordinator
At each workstation, an operator mounts both wheels on their side of the car. Over a shift, up to 440 cars are fitted — that’s 880 wheels total, weighing between 20 and 25 tonnes combined.
“Legislation allows an employee to lift a total of 10 tons over an eight-hour shift,” says Lucie Vacková. “At Škoda Auto, manipulators are standard. They eliminate the risk of injuries, improve workplace ergonomics, and increase both safety and comfort.”
Once the wheels are in place, another futuristic tool comes into play. The operator uses a device that tightens all the bolts simultaneously. It's reminiscent of a racing pit stop — except this five-arm wrench is even more advanced than what you see in Formula 1.
There are many more instances in Škoda’s production where technology assists with large, heavy components.
Watch in the video how the dashboard, which weighs around 60 kg, flows smoothly into place. The Elroq’s fully equipped doors weigh between 35 and 40 kg and require absolute precision — made easy thanks to smart handling tools.
