Small-batch SKD assembly line for light trucks and passenger cars/SUVs

This SKD (Semi-Knocked Down) assembly line is specifically engineered for low-volume, flexible manufacturing of light trucks and passenger vehicles, including sedans and SUVs. Unlike conventional high-volume automotive plants, this versatile system is designed to handle small batch production runs efficiently, making it particularly suitable for emerging markets, pilot projects, or specialized manufacturing operations. The line processes SKD kits wherein major vehicle components—such as powertrains, chassis modules, and body panels—are partially assembled at the origin factory, then shipped to the destination facility for final assembly, testing, and quality verification. Its modular, scalable architecture enables rapid deployment and commissioning while requiring significantly lower capital investment compared to full-scale CKD operations or greenfield manufacturing facilities. The production system features quick-change tooling, adjustable workstations, and flexible material handling systems that accommodate mixed-model assembly, allowing seamless transitions between light commercial vehicles and passenger cars. This approach optimizes logistics efficiency, reduces import duties and shipping costs, satisfies local content regulations, and provides manufacturers with a cost-effective, agile entry strategy into regional automotive markets without committing to large-scale production volumes or extensive infrastructure development.

Small-batch SKD assembly line for light trucks and passenger cars SUVs
SKD Assembly Lines for Light Trucks, Cars & SUVs

Small-batch SKD Assembly Lines

Light Truck & Car & SUV Separate Production Lines

These two sets of SKD (Semi Knocked Down) assembly lines are independently designed for small-batch customized production, dedicated to light trucks and passenger cars (cars & SUVs) respectively. Each line is optimized for the product characteristics and assembly processes of its own category, with the core advantages of quick model change, flexible production rhythm and high assembly precision. Adapted to the annual small-batch production demand of 3,000-20,000 units per line, it fully meets the trial production, regional assembly and customized order needs of automobile enterprises, with low equipment investment and high production line utilization.

1. Light Truck Special SKD Assembly Line

The light truck special SKD assembly line is tailored for the assembly characteristics of light commercial vehicles, optimized for the structural features of light truck chassis, heavy load and modular parts. The production line adopts heavy-duty flexible trolley flow and reinforced quick-change fixtures, which can adapt to the assembly of light trucks with different tonnages and wheelbases, and the whole line follows the assembly logic of “chassis priority, heavy parts pre-assembly”, ensuring the assembly stability and structural strength of light trucks.

The line is specially equipped with heavy part hoisting and assembly auxiliary equipment, reducing the labor intensity of manual assembly, and the model change only takes 40-60 minutes. It fully meets the national industrial standards for light commercial vehicle assembly, and is suitable for small-batch production of fuel and new energy light trucks.

Core Advantages

Heavy-duty Flexible Compatibility

Compatible with 3.5-7 ton light trucks, including flatbed, box and stake models, with reinforced fixtures to ensure chassis positioning accuracy.

Heavy Part Assembly Optimization

Equipped with mobile hoists and lifting platforms, specially optimized for the assembly of heavy parts such as light truck engines and axles.

Quick Change for Chassis Models

Quick-change fixtures for different wheelbases (2800mm-4200mm), no civil construction transformation for model switching.

Dual Energy Type Adaptation

Seamlessly compatible with diesel, gasoline and pure electric light trucks, with independent assembly nodes for power systems.

Core Assembly Process

01. Chassis Frame On-line

Light truck chassis frame on-line, precise positioning by reinforced quick-change fixtures and matching heavy-duty flexible trolleys.

02. Powertrain Assembly

Assembly of engine/motor, gearbox, drive axle and other core powertrain parts with torque-controlled tightening.

03. Chassis Accessory Fitting

Assembly of suspension, braking, steering systems and tires, connection and detection of oil/gas/water pipelines.

04. Cargo Box Assembly

Assembly and fastening of cargo box (flatbed/box/stake) and body accessories, with gap and surface difference detection.

05. Electrical System Connection

Complete the connection and debugging of the whole vehicle wiring harness, instrument panel and lighting system.

06. Fluid Filling & Testing

Precise filling of various fluids, and completion of chassis pipeline pressure test and leakage detection.

07. Whole Vehicle Debugging

Debugging of braking, steering and power systems, ensuring the normal operation of all functional parts.

08. Off-line Inspection & Delivery

Comprehensive inspection of the whole vehicle, qualified products are off-line and enter the subsequent delivery link.

Core Equipment Configuration

  • Heavy-duty flexible trolley: Load capacity ≤15 tons, with reinforced positioning device for light truck chassis
  • Mobile hoist: 1-3 tons load capacity, for the assembly of heavy parts such as engine and drive axle
  • Torque-controlled tightening tools: Electric torque wrenches with data recording for chassis bolt fastening
  • Special quick-change fixtures: Fixtures for different wheelbase light truck chassis, quick switching in 40 minutes
  • Fluid filling equipment: Mobile filling machine for diesel, coolant, brake fluid and other fluids
  • Pipeline detection equipment: Air tightness and pressure detector for light truck chassis oil/gas/water pipelines

2. Car & SUV Special SKD Assembly Line

The car & SUV special SKD assembly line is optimized for the assembly characteristics of passenger vehicles, focusing on the precision of body fitting, the modularization of interior and exterior parts, and the debugging of electronic systems. The production line adopts light flexible trolley flow and precision quick-change fixtures, adapting to the assembly of compact to medium-sized cars and SUVs with different wheelbases, following the assembly logic of “body-chassis combination first, interior and exterior follow”, ensuring the assembly precision and appearance quality of passenger vehicles.

The line is equipped with precision assembly auxiliary equipment for interior and exterior parts, with a model change time of only 30-45 minutes, and is specially optimized for the assembly of new energy passenger vehicles (EV/HEV). It meets the national passenger vehicle assembly standards, and the whole line pays more attention to the fitting accuracy and sensory experience of the whole vehicle, suitable for small-batch production of fuel and new energy cars and SUVs.

Core Advantages

High-precision Body Fitting

Precision fixtures ensure body-chassis combination accuracy, with a fitting gap error of less than 0.5mm.

Modular Interior & Exterior Assembly

Modular assembly nodes for interior and exterior parts, improving assembly efficiency and consistency.

Faster Model Change

Precision quick-change fixtures for passenger vehicles, model switching in only 30-45 minutes.

New Energy Optimization

Independent assembly and debugging nodes for battery packs and electric control systems of new energy vehicles.

Core Assembly Process

01. Chassis & Body On-line

Passenger car chassis and body parts on-line, precise positioning by precision quick-change fixtures.

02. Body-Chassis Combination

High-precision combination of body and chassis, fastening with torque-controlled tools and precision detection.

03. Powertrain Assembly

Assembly of engine/motor, gearbox and battery pack (for NEV), with powertrain debugging.

04. Chassis Accessory Fitting

Assembly of suspension, braking, steering systems and tires, completion of chassis pipeline connection.

05. Interior Parts Assembly

Modular assembly of instrument panel, seats, door interior, ceiling and other interior parts.

06. Exterior Parts Assembly

Assembly of bumpers, fenders, glass and other exterior parts, with body sealing and gap detection.

07. Electrical & Fluid Filling

Wiring harness connection, electronic system debugging, and precise filling of various fluids.

08. Final Inspection & Off-line

Comprehensive inspection of appearance, performance and electronic systems, qualified products off-line.

Core Equipment Configuration

  • Light flexible trolley: Load capacity ≤8 tons, precision positioning for passenger car body and chassis
  • Precision tightening tools: High-precision electric torque wrenches for body and interior part fastening
  • Passenger car quick-change fixtures: Fixtures for 2500mm-3000mm wheelbase models, quick switching
  • NEV special equipment: Battery pack lifting and assembly tool, electric control system debugger
  • Precision filling equipment: Miniature mobile filling machine for passenger car special fluids
  • Body detection equipment: Appearance gap detector, body sealing water test bench and electrical detector

General Advantages of Two SKD Lines

Small-batch Efficient Production

Optimized for 50-500 units per batch, flexible production rhythm, no large-scale automated equipment investment.

Low Investment & High Cost-effectiveness

Based on “manual + simple automation”, the construction cost is reduced by more than 60% compared with traditional lines.

Simplified Quality Control

Simplified quality control nodes adapted to small-batch production, ensuring assembly quality and efficiency.

Easy Operation & Maintenance

All core equipment is mature and general, with simple operation and low later maintenance cost.