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