Manufacturing: - Sequence, Welding and Assembly

Objective:-

1. Explain how a car is assembled on the manufacturing line

2. What are the various processes it basically goes through during assembly?

Introduction
Assembly Sequence:-

Automobile final assembly plants are usually divided into 3 major departments:
The plant will be built as a one-story structure, including office space for management, technical, and other
staff. Automobile final assembly plants are usually divided into three major departments:
(1) body shop,
(2) paint shop, and
(3) Trim-chassis-final. This plant will be organized accordingly.

Body Shop Storage Paint Storage Trim Reprocess

Buffer Shop Buffer Chassi .
s Final
1. Body Shop:-
• Where all BIW parts, sub-assemblies, weld joints, self-piercing rivets, all aluminum parts and spot
welds for steel parts are connected to each other.
• About a thousand spot-welds are made in the body shop. To begin the assembly, the individual sheet
metal parts, consisting of the floor pans and side panels, are loosely fastened together by human
workers.
• The car body then moves through a series of spot-welding operations, both robotic and manual, to add
more parts and permanently assemble the body.
• After the sheet metal body is completed the car bodies move into the paint shop.

Assembly Sequence: - Body Shop: - BIW

We will learn assembly sequence of body shop one by one
➢ BIW refers to the stage in automobile manufacturing in which a cars body, sheet metal components,
have been welded together.
➢ BIW is term before painting and before moving parts e.g. doors, hoods, indicators as well as the engine,
chassis subassembly or trim like glass, seats, electronics etc. have been assembled in the frame
structure.
➢ The increasing presence of automation and Robotics in Automotive manufacturing is a well known
Fact and no other aspect of automotive manufacturing drives more automation than in BIW.
➢ In todays advanced automotive Factory almost all manufacturing operations for BIW are performed
by robots as auto maker pursue modular plat form strategies to consolidate the Global car programs.
 ➢ It essential the BIW assembly process are flexible, support reuse and can adapt changes quickly.
➢ Main operations performed in Body Shop are mostly spot Welds and stud Welds to join the different
panel of vehicle.

2. Paint Shop:-
• Complete BIW structure with BIW closure, assemblies go through wash process, electro discharge,
primer coating process and get celling process and color painting process.
• In the paint shop, a series of processing steps are performed to prepare and coat the car
Body surfaces. These steps are: (1) phosphate, (2) prime, (3) base coat, and (4) clear coat.
• The phosphate process chemically cleans the surface and prepares it to accept the paint coat.
• The priming operation adds the first coat of paint.
• Base coating is the coat that provides the color to the automobile car body.
• The clear coat is applied to enhance luster and complete the coating process. The paint shop is
organized into four sections, corresponding to these steps.
• Between the sections, there are drying and cooling areas.

Assembly Sequence: - Paint Shop: - BIW Painting

BIW Surfaces are required to be painted with the following codes depending upon functional requirement
1) Primer: - The first code to be applied.

• The main functions of the primer are to act as level, act as a protector and make it easier to apply the best coat
the component it's applied on.
• The levelling effect is important sense the surfaces often are marks and other forms of surface defects, after
being manufactured.
• The smoother surface is created by levelling out the defects and therefore a better final product.
• As the Protector, the primer can protect from corrosion, heat differences, stone chips, UV light, etc.
2) Base Coat (BC):-
• The base coat is applied after the primary coat.
• This coat contains the visual property of color and effects and is usually the one refer to the paint.
3) Clear Coat: -
• Usually spread on the top of color or base coat, is Glossy and transparent coating, that forms the final
interface with the environment. For this reason it must be durable enough to resist operation and
chemically stable enough to withstand UV light.
• Clear coat can be either solvent or water form.

Paint Shop
3. Trim Chassis Final:-
• All loose items like electrical unit, brackets, bumpers etc. is directly fit to BIW or assembled to the
body.
• Paint shop must be physically separated from others because of cleanliness, processing and ventilation
problems associated with spray-painting Technology.
 • In addition, there will be a fourth department Reprocess shop is to fix those car needing repair as they
exit Trim Chassis-Final.
• Seats, Dashboard, Windows, and other trim are added. Radios and options such as air conditioning are
also added here. Near the end of trim-chassis-final, the engine, transmission, and tires are mounted
into the car.

Trim and Final Assembly:-

After paint shop all trim in final parts gets joints and vehicle assembly is completed.
1. Body Harness

2. Tailgate Assembly
 Metal Tree (Assembly Line Sequence)
Outer Body/ Reinforcement / Closers:
Assembly Family Structure Tree