Manufacturing process & assembly of automobile

• OUR PROJECT IS ON MANUFACTURING PROCESS OF AUTOMOBILES.

• HISTORY OF AUTOMOBILE STARTED WITH THE FIRST STEAM, ELECTRICAL,WIND-MILL, POWERED AND GASOLINE CARS.

• HERE WE ARE GOING TO DESCRIBE ABOUT VAROUS PROCESS BEING CARRIED OUT WHILE PRODUCTION OF AUTOMOBILE.

THE CHASSIS PRODUCTION UNIT.

THE E-COATING

THE SURFACE FINISH CENTER.

THE PRE-ASSEMBLY.

THE FINAL ASSEMBLY LINE.

BUILDING A FRAME OR BODY IS MOST CHALLENGING WORK.

AN AUTOMOBILE’S BODY IS MADE UP OF ALUMINIUM RATHER THAN STEEL WHICH MAKES THE BODY STIFFER AND SAVES THE CARS WEIGHT.

THERE ARE AROUND 2000 WELDS IN CHASSIS PRODUCTION WHICH ONLY WELL SKILLED WORKERS CAN PERFORM IT.

• AFTER CHASIS PRODUCTION..

• THE CAR’S BODY IS MOVED TO ANOTHER UNIT WHERE IT IS PROTECTED BY CORROSION.

• THE BODY IS SUBMERGED IN CHEMICAL WHERE IT IS ROATED IN 360 DEGREES TO GET COATED FROM INSIDE AND OUTSIDE.

• THE COATING IS OF: NICKEL MANGANESE ZINC• THEN THE CAR IS EMERGED IN AN ELECTRICAL CHARGE

SOLUTION WHERE THESE COATING STICKS TO THE BODY LIKE APERMANENT MAGNET AND PREVENTS IT FROM RUSTING.

HERE THE WORKERS BUILD THE MAJOR COMPONENTS OF CAR LIKE:

DOORS. INSTRUMENT PANNEL. THE ENGINE.

THE WORKERS POLISHES THE BODY AND MAKES A PERFECT FINISH.

THEN AN INSPECTOR INSPECTS IT AND EVEN THE SLIGHTEST AND MINOR MISTAKES DOES’NT MOVES THE CAR TO ANOTHER UNIT.

THE FINAL ASSEMBLY LINE IS LATER DIVIDED IN 7 UNITS:

HERE ASSOCIATES INSTALLS BLOCKS OF HIGH DENSITY FOAM AND THIN SOUND PROOFING SHEET LIKE MATERIAL TO PREVENT LOW AND HIGH FREQUENCY NOISE.

IN THIS SECTION,WIRING IS DONE ALL OVER THE BODY WHICH POWERS AND CONTROLS CARS ALL ELECTRONIC COMPONENTS

HERE THE TECNICIANS INSTALLS STRONG AND STIFF INSTRUMENT PANELMADE OF CAST MAGNESIUM WEIGHING UPTO 15 POUNDS.

1. Production becomes very fast.

2. The product obtained is relatively perfect.

3. Chances of faults and mistakes are negligible.

4. Human or manual efforts are reduced to greater extent.

5. The production takes place very systematically and in a proper sequential order as it is desired.

6. Accidents occurring due to operations like cutting, drilling, grinding, etc are very rare.

7. Objects like glass and such other heavy and fragile parts can be handled by robots.

8. The automobile firms gain profit as they have to spend more money on human workers so they prefer to have robotic and computerized production.

9. Automobile firm owners have a big benefit of these that they don’t go on strikes.

10. The product gained by the automated, computerized and robotically manufacturing is comparatively very advanced.

1. Due to the installation of robotic and computer operated machining there has been a substantial decrease in the employment of skilled workers.

2. There are problems like lower build qualities.

3. Higher initial capital investment.

4. Assembly lines typically cannot modified easily or cheaply to create different products, resulting in inflexibility.

5. Sometimes an assembly line can also allow a robot to do the work of many, which may lead to a loss of overall production.

The automotive manufacturing processes play a major role in deciding on the vehicles’ design characteristics and the overall cost. Thus it is very important for designers and engineers to understand the current manufacturing infrastructure available in their company’s production lines. This will pinpoint the manufacturing capabilities and limitations. At the end of the day, the designer will specify the design tolerances but the machine will control the achieved tolerances.

Also, we finally come to the conclusion that automated manufacturing and assembly of automobiles have relatively much more influence in terms of quality as well as performance.

Megastar Chiru-The Automotive Body Manufacturing Systems and Processes.

National Geographic Channel-Ultimate Factories-Rolls Royce

Wikipedia

ANY QUESTIONS………………?????