The production process flow of aluminum alloy control arm in new energy vehicles was analyzed. A virtual simulation environment of the production line was constructed based on the FANUC ROBOGUIDE platform. The layout of the production line and the robot movements were simulated and optimized in the single-station scheme. The production time of each single process was obtained, and the roll forging process was identified as the key bottleneck. To improve the production efficiency, a process integration strategy was proposed. The bending/flattening and pre-forging/final forging processes were integrated into two double-station forging presses respectively, forming a single-machine double-station optimization scheme. The virtual simulation verification results show that the balance rate of the optimized production line is increased to 87.2%, with an increase of 9.3%. Although the production cycle is slightly increased by 4.1%, the equipment investment is significantly reduced, and the estimated comprehensive production cost is decreased by about 30%. This scheme effectively achieves a balance and optimization of cost and efficiency, providing a virtual verification method and an efficient cost-reduction layout model for the design of automatic production lines for aluminum alloy control arms and similar forgings.