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INTRODUCTION
The Assembly Frame is the section where all Parts are assembled to the vehicle frame to yield a finished car. The painted body frame from Paint Department is received at the first station of the AF line. As the frame progress through the line various parts are mounted and assembled in it. The car coming out of the final station is complete and is sent to Vehicle Quality Department for final inspection. The Assembly Frame is divided into 5 basic lines Trim 1 Trim 2 Chassis Line Final Line Sub-assembly lines The various sub-assembly lines include: Door sub-assembly Engine sub-assembly Instrument panel sub-assembly Tire sub-assembly Rear suspension sub-assembly Fluid & brake pipe sub-assembly Windshield sub-assembly
A common A.F Line is used for the 3 cars Civic, City & Accord. Parts & Sub-assemblies are brought from the respective departments / warehouses by the Material Services Department to the Line side at respective stations where they are assembled. In General, the production lot sizes per day for the 3 models are City 60 Civic 60 Accord 30
YARD
CQA
PARTS RECIEVING DOOR
ASSY
PAINT
WELD
WAREHOUSE
PARTS RECIEVING
DCC1 A.F
ENG. ASSY
DCC1 LAYOUT
1 3 4
1. 2. 3. 4.
Instrument panel sub-assembly Tire subassembly Windshield sub-assembly Fluid & brake pipe sub-assembly
LINE ORDER
T2-03 02 15 05 06 16 17 13 10 11 13
CH-02 07 11
TRIM 1
TRIM2
CH
CH-01 04
T1-01 04 04A 15 16 06 21 20 19 11 13 18
T2 04 01 14 08A 07 08 09
OVERHEAD CONVEYOR
FL-13
09
17
16
05
02
01
CH-16 15 10 05 09
VEHICLE QUALITY
FINAL LINE
CH
FL -012A 12 10 15 08 18 14 06 04 03
CH-17 15 13
TRIM 1
First major line in A.F. This line includes 21 stations. The finished body frame from the Paint Shop enters the first station. The Doors are detached here and sent to the Door Sub Assembly. As the frame proceeds through the line, various parts are assembled manually at each station.
The major parts assembled in Trim 1 for Civic are Insulators (Engine and Dash-Board) All electrical wirings and harnesses (Engine, Floor and Trunk) Fuel and Brake pipe systems Power Steering Oil assembly Engine Fuse-box Front wind-shield wiper assembly Canister Master Cylinder Modulator assembly (ABS) Trunk springs Hood lock assembly Horn ( Low & High ) Fuel filler pipe and cap Rear speakers and Antenna assembly Car emblems
The major differences in parts assembled at Trim-1 for the other models are City: EPS ( Electric Power Steering ) installed in T1 No Upper Arm installation in T1 No wiper Assembly fitment Modulator absent No canister fitment in T1
TRIM 2
The next major line in A.F is Trim 2. This line includes 21 stations. Predominantly Car interiors Accessories are assembled on this line.
The major parts assembled here for Civic are Floor carpet Trunk lid lights Pedal assembly (clutch, brake and accelerator) Tail lights Seat belts SRS fitment* HVAC assembly installation Head lights Dash board or Instrument panel assembly fitment Resonator All garnishes Radiator and condenser installation Gear knob and hand brake fitment Sun visor Door Seal FR & RR Bumper * For SRS Unit installations computerized Torque guns are used. This ensures that the nuts are tightened to the specified torque. The major differences in parts assembled at Trim-2 for the other models are City: Wiper Assembly installation in T2-01 No SRS unit fitment Canister fitment in T2 ECU installation in T2 Trunk Opener is fitted in T2
The major parts assembled here for Civic are Rear Suspension Assembly docking Front Axle Assembly docking Fuel Tank installation Rear STABI installation Exhaust Pipe Assembly fitment ( Muffler & Catalytic Converter ) Tire fitment Brake Oil Modulator Coupler Communication Hand brake wiring ABS Sensors The major differences in parts assembled at Trim-2 for the other models are City: No ABS Sensors fitted Rear Upper Arm Installation Position of Fuel tank is different Rear Axle Assembly is different Rear Brakes Drum Type
Accord: Rear Axle Assembly is different Fuel tank fitted in the Rear Axle Assembly
The major parts assembled here for Civic are: FR & RR Seats Fitment Fr & RR Windshield Fitment Front Qtr Glass Fitment Drip Molding ECU installation Torque Rod fitment Trunk Garnish Air Cleaner Battery Tool Kit Steering wheel assembly Door assembly Wiper Arm Blade Fitment Refrigerant filling Coolant filling Petrol filling Immobilizer Settings The major differences in parts assembled at Trim-2 for the other models are City: No ECU fitment Engine Fuse Box installation No Power Steering Oil filling Accord: PGM-FI Fuel Leakage testing
SUB ASSEMBLIES
1. REAR SUSPENSION Two stations used for assembling rear suspensions. These stations are present in the beginning of the chassis line. The Various parts assembled are: Knuckle Caliper Bearing Fitment Sensor bracket ABS sensor Flash guard Half bearing Brake Plate fitment Hand brake wire Trailing arm
2. INSTRUMENT PANEL
Nine stations are used for complete assembly of the instrument panel. These stations are present in DCC1. The Various parts assembled are: Beam Comp Steering Hanger Dashboard Fuse Box Dashboard wire harness Dashboard fuse box Instrument panel installation Combi-meter Speedometer Sensor Fitment Pad Assembly fitment SRS airbag unit Center panel Heater Control Steering Column Assembly Meter display cover Glove box
3. WIND SHIELD
Wind shield sub-assembly is also done in DCC1.
Two stations are used. The Various parts assembled are Clip fitment Dang fitment Molding fitment Seal fitment Primer application Fastener fitment (for rear mirror)
4. TYRE
Tire sub-assembly is done in DCC1. Three stations are used. Assembly of all four wheels of the car is done here. The Various parts assembled are: Alloy wheel mounting Soap solution application Tire Inflation (44 psi) Wheel balancing
5. DOOR
Twelve stations are used for door subassembly. Doors are removed from the painted body frame entering TRIM 1 and are sent to the sub-assembly stations. On complete assembly they are reassembled in the car at the final assembly line. The Various parts assembled are: Sub Seal Regulator Harness installation Door Checker Door Seal Sealer Application Outer Handle fitment Inner Handle fitment Quarter glass Door lock Run channel Mirror fitment 9
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AE LAYOUT:
AE OFFICE
Transmission Line
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Station 10: Mission docking The transmission unit received from the Mission sub-assembly is installed first followed by the Starter Motor. Station 11: Oil filter Oil Filter Holder is installed followed by the Oil Filter is installed. The cylinder head gasket and oil pressure switch are also fitted here. Station 12: Cylinder head docking The cylinder head sub-assembly is fitted over the cylinder head gasket. Station 13: Cylinder head tightening Cylinder Head Assembly is then tightened to the specified torque. After that Spool Valve is fitted. Exhaust Manifold Gasket is also inserted. Station 14: Rocker arm sub assembly installation Cam Shaft is installed on the Cylinder head. Cam Holder Assembly is then installed and tightened to the specified torque. Station 15: Timing chain fitment Here Tensioner Comp C chain, Guide Comp C Chain and Pulsar Plate are installed. Station 16: Chain case installation Water Passage and Chain Case are installed after 3-bond application. Station 17: Tappet clearance setting Tappet clearance is set for cylinders 1 and 3 after crank pulley installation (with a parallel key).This is done using feeler gauges and a manometer. Station 18: Water leak test Station 19: Tappet setting Tappet Clearance of cylinders 4 and 2 is set. Station 20: Crank pulley angle torque Cylinder Head Cover is first installed followed by Pipe, Tube PCV and Oil Level Gauge. Crank pulley is then tightened (angle torquing). Station 21: Oil leak test Station 22: Engine harness fitment
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Station 23: Exhaust manifold Spark Plugs are installed first followed by the heater baffle Plate. Then the exhaust manifold and manifold cover are installed. Station 24: Engine unloading Station 25: Ignition coil install First mission oil is filled. Then Spark Plug Coil is installed. Station 26: P.S. pump Here P/S Pump is installed. Station 27: Compressor assembly Here Stay Exhaust Manifold is installed. Then Compressor Bracket and Compressor Assembly are installed. Station 28: AC generator assembly Engine Oil is filled. Then Stay Inlet Manifold is installed. ACG assembly and compressor belt are also installed. Station 29: PDI (pre dispatch inspection) A completely assembled engine is the checked thoroughly. All bolts are checked for proper tightening. The engine is also checked for loose parts, missing parts etc.
TRANSMISSION LINE:
The transmission casing is brought to the line At first station the bearings and the dowels are fitted into the casing with the help of a pneumatic press Then the gear shafts (main and counter) are fitted into the casing followed by the fitting of the shifter levers and the forks. Then the cover is put on the whole assembly with sealer applied on the mating surfaces. It is then bolted down with the help of pneumatic guns. After the assembly is complete the transmission unit is transferred to the main assembly line where it is mounted on to the engine.
PISTON SUB-ASSEMBLY:
The piston head is taken and the piston rings are inserted into their respective grooves. The connecting rod is then fitted to the piston head using the piston pin. In City the gudgeon pin is press fitted into the piston con-rod assembly.
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For Civic and Accord cir-clips are used to hold the piston pin within the piston con-rod assembly.
Before assembling the piston and connecting rod care must be taken to check that both their model marks match.
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CONNECTING ROD BEARINGS SELECTION: The various steps involved in selection of connecting rod bearings are explained with an example: Observe the crankshaft and note down the crank pin code. This code comprises of 4 alphabets (A to D). Eg: BBBB Note the code on the 4 chosen connecting rods. Each connecting rod has 1 numeric code. Eg: 2, 2, 2, and 2. These are plotted in the bearing fitting table and the points of intersection gives the color of the bearing to be used.
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MAIN JOURNAL BEARING SELECTION: The various steps involved in selection of main journal bearings are explained with an example: Observe the crankshaft and note down the crankshaft code. This code comprises of 5 numerals (1 to 5). Eg: 33222 Note the engine block code. Eg: DCDDD These are plotted in the bearing fitting table and the points of intersection gives the color of the bearing to be used.
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Principle:
All openings in the water (coolant) galleries are sealed or closed. One opening is fitted with an air hose which fills the coolant channels with air at a specific pressure (Set Pressure XX Kgf/cm2). The system is then allowed to stabilize for 5 to 10 seconds. The same volume of air is pumped into a master cylinder (in the water leakage tester) at same pressure. The system is also allowed to stabilize for a few seconds. The 2 pressure systems are separated by a thin, sensitive membrane present in the machine. If there are any leakages in the engine, the air pressure in the channels decreases. This causes an imbalance across the membrane, causing it to deflect. This membrane deflection is suitably calibrated to indicate the amount of leakage in the engine.
PROCEDURE Install water leak fixture. Turn on water leak start switch. Check leak value and indication lamps.
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Remove connections.
The fixture must complete the water circuit which includes: Air flow tube. Outlet cover stopper. Hose input stopper. Con pipe stopper RACV tube stopper.
Water Leak Tester The Quality checks done are Set Pressure All Lamps Check Channel Check Set Time 0.4 Kgf/cm2 On Model (3 for City, 1 for Accord) City Charging Time: 15 sec Balance Time: 5sec Accord Pressurizing Time: 15 sec Balance time: 7 sec City/ Accord Detecting time: 5 sec City -0.4 - + 0.4 Accord -1.0 - +1.0 No damage of Surface and hose
0.2 Kgf/cm2 On Model (3 for City, 2 for Civic) City Charging Time: 15 sec Detecting Time: 15 sec Accord Charging Time: 20 sec Detecting Time: 10 sec CITY Upper Limit: 75 cc/sec Lower Limit: 10 cc/sec ACCORD Upper Limit: 55 cc/sec Lower Limit: 5 cc/sec no damage of Surface and Hose
NOISE DETECTION No special equipment is used for abnormal noise detection. Noise abnormalities include Tappet Noise in cylinder head Transmission noise Knocking Timing belt & chain related noise Idle pulley noise Compressor belt noise Piston noise Injector noises APPEARANCE CHECKS Visual inspection of the engine is done to check for: Missing parts. Wrong parts. Gauge oil level. Oil purity. Differential seal cap. Coupler engine harness. Charging lamp.
The other tests carried out in this station are The efficient working of the AC generator is checked by measuring the current and voltage produced by it. This is done using the Ammeter and Voltmeter present in the firing bench, the standard values being: Voltage: 14.9 -15 volts Current: 5 amperes The engine is started and allowed to run at an idle speed of 750 (+ or 50) rpm. During this time the starter motor is checked. The transmission is checked for smooth gear shifting.
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VEHICLE QUALITY
INTRODUCTION:
VQ or Vehicle Quality Department is responsible for quality assurance. The main objective of this department is the assurance of good quality products to customers. This department is responsible for performing comprehensive quality checks, inspections & repair-works (if necessary) on all cars before they are dispatched to the dealers. The major responsibilities of this department include: 100% inspection of all vehicles for the quality parameters of Paint, Weld, Assembly Frame, Assembly Engine, Material Services and Parts Quality based on the QS (Quality Specifications)and OPS (Operation Standards) through CVIC (Complete Vehicle Inspection Card). Preparation of defects per car reports and communicating them to various in-house departments. Compilation of PCR reports (Problem Counter-measure reports) and implementation of new systems. Defect rectification carried out at CQA Department (Car Quality Analysis) based on online feedback information. Problem diagnosis during road tests. Leakages checking during shower tests. The V.Q line starts at the point where A.F line terminates. Every vehicle entering the VQ line is assigned a CVIC card. The CVIC card of each car is preserved for 15-20 years as per legal requirements. After thorough inspection of the vehicle at VQ Department the vehicle is temporarily stored at the CBU Yard before final dispatch.
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Feedback and Emission Check Road Test Shower Test CBU Yard
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STATION-WISE ACTIVITES:
1. PAINT INSPECTION INTERIOR & EXTERIOR: Paint quality defects such as Dust, Peel off, scratches, Sag, Lint, Paint Drop and Craters are checked. Sheet metal defects such as Dents, Cracks and Burrs are also checked.
2. INTERIOR INSPECTION: The interiors are checked for improperly fitted, missing, broken or damaged Parts. The major inspection items include Rear view mirror. Seat installation. Head rest. Dashboard. Roof lining. Floor mat.
3. EXTERIOR INSPECTION: Two basic checks are performed for exterior inspections are: Gap check. Flushness check. These are performed to check for weld body alignment defects. Gap specifications are provided for each part and are checked accordingly. Doors, hoods, fenders and bumpers are checked for proper alignment and flushness. 4. G-SWAT: In this station wheel alignment is performed. Wheel alignment only includes the adjustment of the TOE-IN or TOE-OUT to the specified limits for each model. In case of CIVIC & ACCORD the adjustments are made for both front and rear wheels. But for city adjustments are made only on the front wheels. Instruments called Cycles are attached to each wheel for measuring the TOE values which are displayed on screens. The operator then adjusts the Tie Rod Nut (Front wheels) & the Rear Axle wheel Nut (rear wheels) for adjusting the TOE values to the specified limits. 26
Steering center checks are also made. 5. HEAD LIGHT ADJUSTMENT: The front head lights are aligned using the Head-Light Aligner. The Sensing unit of the aligner is brought in front of each head light. The high beam light is turned on. The aligner displays the focusing of the head light on a screen. If the focus is not centered with the screen axis, adjustments to the vertical and horizontal screws of the headlight are made. Head-light focus is then rechecked. 6. SRS/HORN PAD FIX: The SRS and horn unit are assembled to the steering wheel. Effectiveness of the horn noise is also checked. 7. STEERING TURN ANGLE CHECK: On this station steering wheel turn angle is checked. The wheel is turned right and then left and the extent of turning in each direction is displayed in terms of Steering Angles on a Screen.
Steering Angle
8. MDT (MULTI-DRIVE TESTER): In this station the vehicle is driven at all gears on free rolling platform. Drive system and brake effectiveness are checked. Proper working of the combi-meter is also checked. 9. SIDE SLIP TESTER: In this station the effectiveness of wheel alignment is checked. Side slip during slow motion is also checked. 10. UNDER BODY & ENGINE ROOM: In this station the tightening torque level is checked for all major joints. Check for consumable leaks, loose connections, Vibrations on mountings, clamping, Wiring Harness check, Battery check etc are also carried out. 11. ROAD TEST: During road test the car is driven on the test track and checked for any
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abnormal drive noises, rattling noises, drive shaft noises and loose joints (both interior & exteriors). The car is also driven on rough roads to check for stability. Cycle Duration time is 10 min. 12. SHOWER TEST: Water leak from major joints, roof, doors, hood & trunk doors are checked. Efficient working of the wipers is also checked. Shower Test specifications: Number of nozzles :42 Water Pressure :2 Kg/square cm. Cycle Time :7 minutes 13. EMISSION CHECK: The emissions produced by the vehicle are checked using an exhaust gas analyzer. Idle emissions: CO :35.%max, HC :600 ppm
VQ EQUIPMENT LIST:
The following equipments are used in VQ Department for performing the above checks: G-SWAT. Steering Angle checking machine. Head Light Beam Check machine. SRS scan machine. Multi Drive Tester (Roller bed). Side Slip Tester. Line End Testing Scan tool (HDS). Water Shower. On complete inspection of the cars they are categorized into the following: RSP Vehicles: Those vehicles in which there were no Quality Defects & have been passed by VQ after thorough inspection & Road Test are called as Royal Straight Pass (RSP) Vehicles. Offline Vehicles: Those vehicles in which there were major Quality observations due to which the VQ inspection would never be carried out to the subsequent stage are known as Offline Vehicles. Observations on Offline vehicles are taken critical note by concerned dept for initiation of Countermeasures
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WELD
DENT REMOVAL
AF and AE
Parts Quality
Paint
REPAINTING
CBU YARD
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SECTION-WISE ACTIVITIES: 1. Body inspection: Removal of body dents and scratches. Inspection of all important weld joints. 2. Paint Repair and Inspection: Dirt and dust removal, Surface preparation, touch up, re-painting of defected areas. Polishing of repainted areas as per needs. 3. AF related inspections: Re-Assembly of parts Study of parts complaints and replacements as per needs. 4. AE related inspections: Engine & Transmission related issues check. Parts inspection & replacement as per needs.
CQA EQUIPMENT:
The following equipments are used in CQA for performing the above checks and repair works: Dent Remover. Surface Preparation including Polishing. Paint Coating & Baking oven. Functional check equipments for HVAC and for Noise Arresting. Assembly related Jigs/Fixtures.
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