Processes of automobile manufacturing

The process of making the automobile from stamping Final Assembly.

1. By Satha . Processes of Automobile Manufacturing

2. 1. Concept design 2. Press Shop 3. Body assembly or Weld Shop 4. Paint Shop 5. Powertrain 6. Final Assembly 7.Demo Video Summary

3. Concept design Brainstorm Study about the Client Research Sketch Concept Development Revisions CAD modelling and analyzing Completion the design

4. Press Shop This is where the production process starts Metal parts getting pressed out of Steel Sheets The door panels, Roof, Bonnet, Boot Lid etc are typically pressed in to form the basic structure of the automobile The pressing process is a multi-step process where the sheets are pressed into shape in stages .

5. Coil transfer Decoiler and strip feed Strip washing plant Adjustment and lubrication Blank removal Material feed Tool changeover Linking presses Press drives Removal of finished parts Scrap recycling Material transport / storage

6. Body assembly or Weld Shop The Weld shop is typically the place where the automobile is born . The welding process is typically  Tungsten Inert Gas (TIG)  welding Done by Robots mostly All these multi axis robotic arms work in unison and utmost precision The output of the Weld Shop is called as a BIW or a Body In White The identity of the BIW comes when it is carved with VIN or Vehicle Identification number

7. Skid conveyor system Access control / securing the area Axis range scanning Turntables Handling Gripping / clamping Cooling water and industrial gases Gluing / sealing Type and part detection Manipulators Body cleaning Body storage area

8. Paint Shop The painting process is one of the most complex and cleanest of process It is completely dust free Pre-treatment where the BIW is dipped into an electrolyte solution which would help in better paint deposition on the Metal Sealant : Prior to the application of paint, the BIWs enter the sealant area where the sealant is applied. Paint Booths : The BIWs enter the paint booths, for the final painting process Oven: The painted bodies are then passed through the oven where the final baking process of the Paint takes place Wax Booths: Where application of a fine layer of wax takes place Polishing : One of the most laborious processes and the most time consuming one as well The longer and more elaborate the Polishing process, the better is the shine. So the costlier the car, the longer would have been the polishing done on it

9. Conveyor technology Pretreatment Cathodic e-coating Sealing / conserving Water treatment Fresh air / Exhaust air Paint recycling Painting robots Painting add-on parts Heat generation and distribution Heat generation and distribution Assembly of add-on parts / final inspection Body storage area

10. Powertrain Heart of the Vehicle The birth of the Engine for a car, typically happens when the Vehicle is in the paint shop Identity of an engine is given when the Engine Block gets machined and the EIN (Engine Identification Number) is punched into the Engine Block The assembly process of the Engine is again precision controlled with various stages of machining the Pistons, fitment of the Piston rings and then lowering the assembly into the Engine Block Finally the Engine Head comes and then the engine undergoes a series of tests includes Leak Test and pressure tests The engines are then " pre-run " in some cases before getting mated to the TransAxle

11. Foundry Mechanical processing 1 (Engine / Gearbox) Mechanical processing 2 (Engine / Gearbox) Component manufacture Coolant preparation / swarf disposal Washing and cleaning parts Leak test Engine assembly Engine test rig Gearbox assembly Gearbox test rig Delivery / storage

12. Assembly This is the last and final stop for the automobile in the production process When out of it, the vehicle is roadworthy with all its parts working in unison providing locomotion This is where most of the fitment is actually done by human hands The complicity lies in making the right parts available in the right sequence of production at the fitment area. (Right Place, Right Time, and Right Sequence is the key to it all) Most of the components of the car like the windshields, trims, Steering Column, electronics and the engine - vehicle marriage happens here Finally after the wheels come in, the vehicle becomes capable of moving by its own power And here the Vehicle undergoes stringent quality tests Following the drive test, the vehicle reaches the yard to dispatch

13. Disassembling the doors Assembly of door module Dashboard installation Windscreen assembly Chassis / driveline assembly Marriage Wheel assembly Seat assembly Reassembling the doors Fuelling Function test Rain test / final inspection

14. https://www.youtube.com/watch?v=hw9JrjsPhT8 Demo Video

15. Thank You