Dongfeng truck KD

project plan
 Dongfeng plant status description

Workshop passageway

Internal passageway Paint line Reserved

36 m U-steel rails area
Pick-up& saloon
combined assembly
Internal passageway
line
Three lifting machines

test line
overhead travelling crane A&B
Reserved area
office Stock area of commodity
vehicles

Workshop passageway Workshop passageway

The length is 143m,width is 60m, space is 9780 square meter.

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 Dongfeng plant KD technics plan

1、boundary condition of technics plan

Plans to produce car models：models:KE5E 、KD4E（D530 platform 4×2cargo truck）

Production capability：2uints per shift；

Working time：244days per year，8hours per day（working time in schedules），8hours per day

（actual working time）；

Takt time：time in assembly 210mins per unit ,adjustment and test time is 120mins per unit；

Definition of KD： delivery under assembly status in chassis sector, delivery under sub -assembly

status in cargo body;

Assembly mode: simple assembly line, fixing the frame upwards, adding cargo body assembly

and component assembly in the foundation of chassis.

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 Dongfeng plant KD technics plan

2、 technics plan design concept

1、The length of former assembly line is 36 M, regards the planed production model
KE5E\KD4E(the length of truck is 8M),production capability, refer to the standard operation mode
of assembly the similar model in DFCV plant, decrease the chassis assembly station from 8 to 6;
decrease the final assembly station from 39 to 3(at the same time considering the possibility of
subsequent assembly heavy truck)

DFCV standard operation Planed Belayab operation

mode mode

final assembly area 39stations 3stations

chassis assembly
area 8stations 6stations
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 Dongfeng plant KD technics plan

2、Ability of body assembly

3、Ability of medium(heavy) truck adjustment and test
4、Make full use of existing conditions：
（1）、length of 36M u-steel rails
（2）、2 units 2 tones overhead travelling crane has the
54M rails
（3）、lights、speed、brake testing equipment

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 Dongfeng plant KD technics plan

3、Operation station layouts

The assembly line is a linear chain , composite of 4 final assembly stations,7 sub-assembly

stations.

The assembly mode adopts frame upwards installed(before the frame loads in the assembly line,

it turnover first, all the components and parts all installed upwards).
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 Dongfeng plant KD technics plan

4、operation station
chassis station station
frame on line and harness assy 1
steering sub-assy 1-1
engine parts assy station 2
pipe/air reservoir/valve/dryer/exhaust pipe sub-assy 2-1
frame lifting/powertrain assy and fuel/oil fill station 3
axle sub-assy 3-1
engine/gearbox sub-assy 3-2
cooling system sub-assy 3-3
cab sub-assy 3-4
body down station 4
body assy 4-1

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 Dongfeng plant KD technics plan

5、renew scheme Plant passages way

3/new 5T crown
block 18m
1、new cantilever Paint line
Plant passages way

Plant passages way

cra0.5t×3.5m×2.8 2、remove the lift
Steel groove guide machine
m

Backup Area
Passenger way

Inspection line
Backup Area

4、KD parts stock 5、truck stock area 6、truck

area adjustment area
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 Dongfeng plant KD technics plan -layout after project

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
Paint line

30m

6m Chassis adjustment area

30m
KD parts stock area Truck stock area

9
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 Dongfeng plant KD technics plan -layout after project

Technology layout ：

Workshop Overall length 143m，width 60m：

1、Chassis assembly line : length 36m，width 6m，total 3 truck space. The line is moved forward by

manual power. The line have 2 units crown block capacity 2ton and 1 new equipment capacity 0.5ton

cantilever crane . logistics channel is between assembly line and inspection line with width 3m；

2、Adjustment Area : Length 30m，width 30m which can meet the chassis inspection；

3、Inspection Line : Length 83m，width 5.8m,with 4 stations: chassis inspection、lamp inspection、

vehicle speed inspection、brake inspection；

4、Body assembly area : length 30m，width 18m : sub-assembly area length16m，body assembly

area length 14m. New equipment: 1unit crown block: capacity 5ton，height 6m，span 18m

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 Dongfeng plant KD technics plan -station and worker

1、station plan：Final assembly line： 3 stations，sub-assembly line have 4 stations，small parts sub-assy
2 station ，body assy：body final assy 1 station，body down and accessory 1 station
2、worker Plan：total 46 workers（assembly worker 41,（include body assy and body down,3）；
adjustment worker 2；assistant 3），details below：
Assembly Area Body assy
Body Sub- other
Final assembly area Sub-assembly area
down assy

Total
2-1 workers
Station 1
Station 3 pipes、air 3-2 4-1
frame on line Station 2 1-1 3-1 3-3 3-4 4
Station frame lifting、main reservoir、 engine、 body sub- adjustment assistant
and harness engine parts steering axle cooling system cab body down
assy and fill oil valves、dryer gearbox assy
assy
exhaust pipe

3
(front 1， 2
8 8 8 2(1 sub-a，1
workers (each side 4) (each side 4) (each side 4)
2 2 rear 1 3人
assistant)
(each 3 2 3 46
assistant side1)
1)

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 Dongfeng plant KD technics plan --chassis

6、Specific technology scheme

One--chassis assy plan（refer to technology layout）：
1、use the pick-up line，divide it into final assy and sub-assy area: final line from（1-10pillars）,sub line from（11-
17pillars）;
2、there are 3 lifting machines on the line now, and must be removed for new plan(reason see later)；
3、frame move on line from2-3 pillars with forklift, finish assy of all parts between 3-8 pillars(except
axle/engine/gearbox/cooling system, cab : these parts will be assembled in sub-assy area) ;
4、when axle is sub-assembled, move to position station on final assy line between pillar 9-10 by 2#crown block
and position front and rear axle, then the frame is lifted and down on the axle by 1#crown block;
5、2# crown block lift transmission shaft/engine/gearbox/cooling system(water tank/radiator)/cab one by one and
down on the station2 for assembling, then fuel and oil will be filled；
6、after final assy，turn right to off line，and drive to inspection area.

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 Dongfeng plant KD technics plan -chassis adjustment&inspection

Specific technology scheme

Two—Chassis adjustment and inspection scheme（refer to below figure） ：

1、Off line truck move to adjustment area（pillar 18-23),finish adjustment work；
2、Truck move outdoor for road test;
3、Truck move to pit 1 after road test , finish lamp/speed/brake inspection on the inspection line,
and can repair at pit 2if have problem；
4、After inspection, qualified truck move to adjustment area and finish adjustment & inspection

Pit 1 Lamp inspection Speed inspection Brake inspection Pit 2

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 Dongfeng plant KD technics plan– body assembly

Specific process scheme

（3）、Body assembly and loading (please see the
picture) :
Add a new 5T Crane, span 18 meters
1、After the chassis completes the adjustment and testing
process, it is parked in the check area, and drive backward
from column 20-23 (6 meters between each column) to
body loading area; Logistic gate size 3.5*4.5,
should be change to 4.5*4.5
2、Parts of the body enter into body assembly area
Body assembly area
between column 22 and 23, here need to add a 5T crane
(span 18 meters), use crane to complete body assembly;
3、The 5T crane should cover the body assembly and
loading areas, and complete the body loading; Body
4、After body loading, truck leave through the path from uploading
area
column 20-23, enter the adjustment area, and leave
adjustment area between column 19 and 20, and also the
19 20 21 22 23
path from column 20-23. -14-
 Dongfeng plant KD technics plan– logistic

7、Logistics scheme design

1. Based on process scheme
2. Considering that the factory also needs mixed production of pick-up truck, need to reserve the
areas for pick-up truck tool, equipment and products.
3. At this stage, it is not advisable to carry on the big transformation to the workshop, for example,
to add the new logistics door.
4. There is no cross between logistics route and inspection line of parts in workshop

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 Dongfeng plant KD technics plan– logistic

Specific process scheme

（4）、 Logistics scheme: the logistics route is one-way, the specific route is as follows (the
red arrow direction in the workshop; the yellow arrow direction outside the workshop; blue
arrow direction is chassis offline ):

Paint line

There is a
cross between
the logistics
route and
chassis offline
route
KD parts storage Original trucks storage
Office
area

Chassis adjustment
area

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