Car Manufacturing Process Pdf

To this point in the process, BMW team members have worked meticulously to prepare the canvas. Now begins the work of our finish team to fill the vehicle with a unique combination of components, options, and luxuries that will make this BMW as distinctive as its owner. This is Assembly, where it all comes together.The body – formed, painted, and protected – waits in the stacker, arranged in order.

1. Car Manufacturing Process Diagram
2. Hyundai Car Manufacturing Process Pdf

Sequenced parts such as instrument panel, front end, and powertrain are at the ready in other areas of the plant. What follows is a careful and intricate performance involving the flow of parts and precisely-timed processes. From this point on, every vehicle has a name. All computers and controls in Assembly are linked together by nearly 16,000 miles of communications cables. Ergonomics are very important in the Tilt area.

In 1908 Henry Ford began production of the Model T automobile. Based onhis original Model A design first manufactured in 1903, the Model T tookfive years to develop. Its creation inaugurated what we know today as themass production assembly line. This revolutionary idea was based on theconcept of simply assembling interchangeable component parts.

Prior tothis time, coaches and buggies had been hand-built in small numbers byspecialized craftspeople who rarely duplicated any particular unit.Ford's innovative design reduced the number of parts needed as wellas the number of skilled fitters who had always formed the bulk of theassembly operation, giving Ford a tremendous advantage over hiscompetition.Ford's first venture into automobile assembly with the Model Ainvolved setting up assembly stands on which the whole vehicle was built,usually by a single assembler who fit an entire section of the cartogether in one place. This person performed the same activity over andover at his stationary assembly stand. To provide for more efficiency,Ford had parts delivered as needed to each work station.

In this way eachassembly fitter took about 8.5 hours to complete his assembly task. By thetime the Model T was being developed Ford had decided to use multipleassembly stands with assemblers moving from stand to stand, eachperforming a specific function. This process reduced the assembly time foreach fitter from 8.5 hours to a mere 2.5 minutes by rendering each workercompletely familiar with a specific task.Ford soon recognized that walking from stand to stand wasted time andcreated jam-ups in the production process as faster workers overtookslower ones. In Detroit in 1913, he solved this problem by introducing thefirst moving assembly line, a conveyor that moved the vehicle past astationary assembler. By eliminating the need for workers to move betweenstations, Ford cut the assembly task for each worker from 2.5 minutes tojust under 2 minutes; the moving assembly conveyor could now pace thestationary worker.

The first conveyor line consisted of metal strips towhich the vehicle's wheels were attached. The metal strips wereattached to a belt that rolled the length of the factory and then, beneaththe floor, returned to the beginning area. This reduction in the amount ofhuman effort required to assemble an automobile caught the attention ofautomobile assemblers throughout the world. Ford's mass productiondrove the automobile industry for nearly five decades and was eventuallyadopted by almost every other industrial manufacturer. Althoughtechnological advancements have enabled many improvements to modern dayautomobile assembly operations, the basic concept of stationary workersinstalling parts on a vehicle as it passes their work stations has notchanged drastically over the years.Raw MaterialsAlthough the bulk of an automobile is virgin steel, petroleum-basedproducts (plastics and vinyls) have come to represent an increasinglylarge percentage of automotive components. The light-weight materialsderived from petroleum have helped to lighten some models by as much asthirty percent.

Car Manufacturing Process Diagram

As the price of fossil fuels continues to rise, thepreference for lighter, more fuel efficient vehicles will become morepronounced.DesignIntroducing a new model of automobile generally takes three to five yearsfrom inception to assembly. Ideas for new models are developed to respondto unmet pubic needs and preferences. Trying to predict what the publicwill want to drive in five years is no small feat, yet automobilecompanies have successfully designed automobiles that fit public tastes.With the help of computer-aided design equipment, designers develop basicconcept drawings that help them visualize the proposed vehicle'sappearance. Based on this simulation, they then construct clay models thatcan be studied by styling experts familiar with what the public is likelyto accept. Aerodynamic engineers also review the models, studying air-flowparameters and doing feasibility studies on crash tests. Only after allmodels have been reviewed and accepted are tool designers permitted tobegin building the tools that will manufacture the component parts of thenew model.The ManufacturingProcessComponents.1 The automobile assembly plant represents only the final phase in theprocess of manufacturing an automobile, for it is here that thecomponents supplied by more than 4,000 outside suppliers, includingcompany-owned parts suppliers, are brought together for assembly,usually by truck or railroad.

Those parts that will be used in thechassis are delivered to one area, while those that will comprise thebody are unloaded at another.Chassis.2 The typical car or truck is constructed from the ground up (and out).The frame forms the base on which the body rests and from which allsubsequent assembly components follow. The frame is placed on theassembly line and clamped to the conveyer to prevent shifting as itmoves down the line. From here the automobile frame moves to componentassembly areas where complete front and rear suspensions, gas tanks,rear axles and drive shafts, gear boxes, steering box components, wheeldrums, and braking systems are sequentially installed. Workers install engines on Model Ts at a Ford Motor Companyplant. The photo is from about 1917.The automobile, for decades the quintessential American industrialproduct, did not have its origins in the United States. In 1860,Etienne Lenoir, a Belgian mechanic, introduced an internalcombustion engine that proved useful as a source of stationarypower.

In 1878, Nicholas Otto, a German manufacturer, developed hisfour-stroke 'explosion' engine. By 1885, one of hisengineers, Gottlieb Daimler, was building the first of fourexperimental vehicles powered by a modified Otto internal combustionengine.

Also in 1885, another German manufacturer, Carl Benz,introduced a three-wheeled, self-propelled vehicle. In 1887, theBenz became the first automobile offered for sale to the public. By1895, automotive technology was dominated by the French, led byEmile Lavassor. Lavassor developed the basic mechanical arrangementof the car, placing the engine in the front of the chassis, with thecrankshaft perpendicular to the axles.In 1896, the Duryea Motor Wagon became the first production motorvehicle in the United States. In that same year, Henry Forddemonstrated his first experimental vehicle, the Quadricycle.

By1908, when the Ford Motor Company introduced the Model T, the UnitedStates had dozens of automobile manufacturers. The Model T quicklybecame the standard by which other cars were measured; ten yearslater, half of all cars on the road were Model Ts. It had a simplefour-cylinder, twenty-horsepower engine and a planetary transmissiongiving two gears forward and one backward. It was sturdy, had highroad clearance to negotiate the rutted roads of the day, and waseasy to operate and maintain.William S. Pretzer.3 An off-line operation at this stage of production mates thevehicle's engine with its transmission. Workers use robotic armsto install these heavy components inside the engine compartment of theframe. After the engine and transmission are installed, a.

On automobile assembly lines, much of the work is now done byrobots rather than humans. In the first stages of automobilemanufacture, robots weld the floor pan pieces together and assistworkers in placing components such as the suspension onto thechassis.worker attaches the radiator, and another bolts it into place. Becauseof the nature of these heavy component parts, articulating robotsperform all of the lift and carry operations while assemblers usingpneumatic wrenches bolt component pieces in place. Careful ergonomicstudies of every assembly task have provided assembly workers with thesafest and most efficient tools available.Body.4 Generally, the floor pan is the largest body component to which amultitude of panels and braces will subsequently be either welded orbolted. As it moves down the assembly line, held in place by clampingfixtures, the shell of the vehicle is built. First, the left and rightquarter panels are robotically disengaged from pre-staged shippingcontainers and placed onto the floor pan, where they are stabilized withpositioning fixtures and welded.5 The front and rear door pillars, roof, and body side panels areassembled in the same fashion. The shell of the automobile assembled inthis section of the process lends itself to the use of robots becausearticulating arms can easily introduce various component braces andpanels to the floor pan and perform a high number of weld operations ina time frame and with a degree of accuracy no human workers could everapproach.

Hyundai Car Manufacturing Process Pdf

Robots can pick and load 200-pound (90.8 kilograms) roofpanels and place them precisely in the proper weld position withtolerance variations held to within.001 of an inch. Moreover, robotscan also tolerate the. The body is built up on a separate assembly line from the chassis.Robots once again perform most of the welding on the various panels,but human workers are necessary to bolt the parts together. Duringwelding, component pieces are held securely in a jig while weldingoperations are performed. Once the body shell is complete, it isattached to an overhead conveyor for the painting process. The body and chassis assemblies are mated near the end of theproduction process. Robotic arms lift the body shell onto thechassis frame, where human workers then bolt the two together.

It should be noted that an automobile is worth more as parts than it is in its whole form. There is a large cost savings when you build a complex auto on an asembly line versus buying individual pieces.

People have always questioned why the parts are so expensive, but the real reason is described above: the asembly line. The asembly line allows for auto manufacturers to build a car as inexpensively as possible because the entire process is stream lined. When you, as an individual, purchase a specific part, you have to think of yourself as one of those specialized craftsmen that were prior to the advancement of the asembly line.(I had to alter the word asembly line because, when I attempted to submit this, it kept saying 'Sorry, bad language is not allowed').