Inside Stellantis’ Sterling Heights Assembly Plant (SHAP) in Michigan, an autonomous robot quietly glides through the warehouse aisles, scanning shelves, capturing images and building a live digital map of every part in sight. Each full scan covers more than 36,000 square feet in less than an hour and the robot makes multiple passes each day.
At SHAP, the Dexory robot and its AI-driven platform, DexoryView, work alongside Stellantis’ workforce to turn warehouse activity into real-time visibility across the facility. With each scan, the system updates material inventory, highlights items that may need attention and provides instant insight into part locations and availability.
The result is reportedly faster, more confident decision-making on the floor that supports accuracy, keeps materials moving and helps teams stay in sync.
"This technology makes material handling more predictable,” SHAP Plant Manager Chuck Padden said. "By catching and addressing part needs before they reach the line, our workforce has accurate, up-to-the-minute visibility so they can focus on vehicle assembly, knowing the right parts are in the right place at the right time.”
The system also supports dynamic slotting, which organizes frequently used parts in more accessible locations.
SHAP’s search for a more streamlined way to support material handling aligned with an annual event that Stellantis hosts to bring forward ideas for plant-level needs. As part of the lead-up to the 2024 Factory Booster Day, SHAP leaders invited participating suppliers to develop solutions that would enhance part placement accuracy, simplify audit activities and keep material moving steadily to the line. Dexory’s autonomous scanning and AI platform emerged as the leading solution.
SHAP became Stellantis’ first North America site to integrate the robot into its body shop, with early success paving the way for expansion to additional facilities, including Detroit Assembly Complex – Jefferson, Toledo Assembly Complex and Warren Truck Assembly Plant, as the company explores broader use across assembly and powertrain operations.
"This is the future of manufacturing – people and technology working side by side,” Dexory's North American Vice President Todd Boone said. "By combining our robots and AI-powered solutions with Stellantis’ expertise, we enable manufacturing with greater precision and efficiency.”
