The document summarizes the body shop and assembly plant processes at Hyundai Motors India. In the body shop, robots are used to weld and assemble different car body parts across four main lines. Quality control inspectors thoroughly check each car body before it proceeds to painting. The assembly plant has 14 sequential stages where major components like the engine, chassis, wiring and trim pieces are gradually installed. Advanced equipment and robots aid in precise assembly and quality is rigorously tested at various stages before cars are road tested and shipped.

1. PROJECT INTERN IN HYUNDAI
Prasanth Nalam
28 November 2014
BODY SHOP
In Body Shop Plant-II, the cars Verna, Xcent, old i10 and Grande i10 are being
manufactured. There are 195 robots deployed in this plant. Out of the 195 robots, 146 are
used for welding and others are used pick and place operations. These are the four lines
in the plant:
1. Moving Line
2. Floor Line
3. Body Build Line
4. Main Build Line
Floor Line is the first line of the body shop. here the body of the car will get floor
built. In theBody Build Line, the car sides, fenders and roof bars are fixed. Then in the
main build line, the body will get the basic shape of the car. Here, the rear part of the car
and the roof are fixed. In the moving build line, the moving parts such as the doors and
bounteous are fixed.
QUALITY CONTROL AND INSPECTION:
In this line of the factory, the employees from the Quality Control
Department will check for the standards and requirements. If a car’s body doesn't passes
these tests, the body is directly scraped and refurbished.
The Plant has a motto of 100% quality and achieves 98%. This 2%
difference is due to the flaws in the metal which happens once or twice a month.

2. PROJECT INTERN IN HYUNDAI
FACILITIES AND OPERATIONS:
The robots deployed here help in the various operations such as Hemming
and Welding.
Hemming - In this process, the shop edges of the body such as the fenders and body
panels are bent and smoothened.
Spot Welding - In this process, two surfaces are kept together and heat is supplied at the
required spot by the robots which fuses them together. The number of welds depends on
the car which is manufactured. In Verna for example, 3800 spot welds are made.
EMR - Electric Monorail System (EMR) are overhead hanger like structure which is used
to transport body from one line to another.
CO2 Welding - This type of welding cannot be done by robots. Hence, it is manually
done.
MATERIALS USED FOR MAKING THE BODY
The two materials used for making the car bodies are:
Galvanised Aluminium - GA is used for light weight chassis.
Cast Iron - CI is a type of mild metal which is used for durability.
The material to be used is different depending on the country to which the
car will be exported.
The cars manufactured in Hyundai Motors India are being exported to
Gulf Countries and European Countries also and will meet requirements of the different
governments.

3. PROJECT INTERN IN HYUNDAI
Prasanth Nalam
28 November 2014
ASSEMBLY PLANT-II
The Assembly Plant in Hyundai has some of the most advanced tools used in the
field of automobile engineering. This plant has 14 stages. These include:-
● Trim Line I
● Trim Line II
● Chassis Line I
● Chassis Marriage Line
● Chassis Line II
● Final Line I
● Final Line II
● O.K. Line I
● O.K. Line II
● Tester Line
● Shower Test
● Road Test
● Touchup & Repair
● Final Inspection

4. PROJECT INTERN IN HYUNDAI
TRIM-I : The parts which should be at the base of the body floor are fixed first. The
electrical wires are fixed followed by the dashboard, roof etc. The doors are removed at
this line so that the workers can freely work inside the body. The doors are sent through
separate lines where the windows and side panels are fixed. Safety measures such as
Airbags and ABS are also fixed in the stage.
TRIM-II : At this stage, Lamp, Headlining, AC tubes, Bumpers, Seat Belts are fixed. All
the fluids such as brake fluid, engine and lubrication oil, AC fluids are filled.
CHASSIS-I : Here, the underbody parts are assembled. They include fuel tanks,brake
tubes, exhaust etc.
CHASSIS MARRIAGE : This is the most important stage of the assembly plant. Chassis
marriage is a process where the car’s body meets the engine, transmission, front and front
axles. This process utilised the most advanced equipments in the plant. The radiator is not
fixed at this stage.
A RGV (Rail Guided Vehicle) will carry all the parts needed to be fixed at the Marriage
stage. The Parts are also pre-positioned accurately on the RGV itself.
CHASSIS-II : This is a small stage where some under components and Torque-Trolley
are fixed.
FINAL-I : Some parts like Steering Column, Tail Gate Glass, Floor Carpet and
Windshield are fixed.

5. PROJECT INTERN IN HYUNDAI
FINAL-II : Here, the FEM (Front End Module) are fixed. These include Radiator &
Subassembly, condenser, carrier and horn are fixed.
OK-I : The tires alone are fixed and wheel alignments are checked at this stage. Now the
car is almost ready.
OK-II : Radiator oils and a little amount of fuel are filled here. The finished doors
assembled at this stage.
INSPECTION : The interiors are visually inspected. The bolts and engine are checked.
The exterior are inspected and the gaps between the exterior body parts are precisely
checked. The tolerance limit of these gaps are (+0.5 , -0.5). Various tests are carried out
at this stage:-
• Tester Line : Here, the wheels alignment, headlamp levelling and errorising are done.
After this, the performance and economy of the car is tested using specialised rollers &
equipments.
• Road Test : For the first time, the car rolls out from the factory. There are private test
tracks which simulate all the conditions such as inclination and declination, rough
terrains, dry and wet roads etc. The car is checked for noise & loose parts.
• Water Test : Rainy conditions under specific pressure and temperatures are simulated.
The pressure is maintained at 2 bar. Leaks are checked.

6. PROJECT INTERN IN HYUNDAI
Touchup & Repair : Both the exterior and interior are checked for scratches and dents.
Dents may occur due to mishandling of tools.
Final Inspections : The whole car is finally inspected and the bolts gaps etc. are checked
here once again.
The cars with scratched or dents will be detained at a separate area where they will be
repaired.

7. PROJECT INTERN IN HYUNDAI
Prasanth Nalam
28 November 2014
ENGINE PLANT
This is the plant where the heart of the engine is manufactured. Hyundai engines are
known for their light-weight and reliability. The Engine Plant consists of the following
stages:
• Block Input - The engine block is pre-assembled at the press shop. The engine is
moulded here at a Foundry. The engine block is moved from the stock area and placed
on the conveyer by a robotic arm.
• RGVS - Robot Guide Vision System (RGVS) will monitor each and every engine
block for flaws and errors. The rejected engines will assemble at the outside of the
conveyer.
• Engine Number G M/C - Here, the engines will get their unique Engine Numbers.
• Turn Over System- This system turns the engine upside down.
• Ladder Frame Removal System - This system will spilt the engine into two parts.
The upper part will be sent through an adjacent conveyer.
• C/Block Washing M/C - Here the engine block is washed with high pressure
water to remove the dirt and impurities accumulated during moulding process.
• The Washing stages are as follows:
● Washing - I
● Washing - II
● Air Blow - I
● Air Blow - II
● Idle
• Oil Pump Assembly - Here, the piston room is lubricated and screws are
loosened.

8. PROJECT INTERN IN HYUNDAI
• The Metal Block Cap is then removed.
• Bearing Check - The bearings in the engine are checked manually.
• Bearing Cap Assembly M/C - The bearing cap is assembled by a system.
• Crank Loading - The crank of the engine is loaded manually at this stage.
• MB Cap Free Tight - Here, the MB Cap is placed again and the screws are
tightened to a little extent by labours.
• MB Cap MR Tight - All the screws are tightened precisely, not too much or not
too loose.
• IPT-I - Internal process tester will check the internal parts like crank and bearings.
• The engine body is rotated again.
• Piston Inserted - Pistons, usually four in number are inserted into Piston Rooms.
• The Connecting Rods are inserted along with the pistons are tightened freely.
• Then Air Tightening takes place which is done by a machine.
• IPT-II - Internal parts, now the Pistons & Connecting Rods are checked.
• Block Sub Assembly - The base block is assembled here.
• Ladder Frame Assembly M/C - The operated parts at the starting of the lane is
fixed.
• L/Frame M/R Tight - The engine’s top and bottom parts are tightened.
• Oil Seal Assembly - The seal will be applied manually.
• Oil Seal Process - The oil seal is done by a machine.
• Oil Pan Sealant - The oil pan is sealed here
• Seal Bolt Check - All the seals are checked here.
• Gasket Loading - The Piston Gasket is placed here.
• Piston Check - The pistons are inspected for free rotations.
• Head Loading - Here, the head of the engine is mounted.
• Head M/R Tight - Machines are used to tight the head.
• Head Lash Assembly - Head Lash are assembled here.
• Cam Shaft Assembly - The camshafts are manually assembled.
• Checking of Can Bore Oil takes place. It should be free from Burr of Corrosion
materials.

9. PROJECT INTERN IN HYUNDAI
• Timing Chain Assembled - The timing chain is loading manually.
• T/C Cover Assembly - The Timing Chain is covered here.
• Cycle Head Cover assembly takes place.
• The Spark Plug and Fuel Injected systems are assembled.
• Thermo-Stat system are assembled
• Damper Pulley Assembled takes place. The damper pulley is connected with the
pistons.
• IPT-III - The internal parts are checked again.
• Crank Shaft Orientation takes place.
• Flywheel is positioned after the crank shaft orientation.
• Flywheel is checked and tightened.
• Free Engine Oil - The engine oil is filled here.
• Alternator id assembled here.
• Engine is tested by Quality Department. The Engine Testing Line has specialised
equipment where the engine is tested at 4000 rpm and noise and economy are tested.