INTERNSHIP REPORT

BODY CONSTRUCTION
FORD INDIA PRIVATE LTD.

VIA S.P.KOIL POST, CHENGALPATTU – 603204

SUBMITTED BY

SYAMALA BONISH S ENOSH

 II B.Tech II B.Tech

MECHANICAL ENGINEERING MECHANICAL ENGINEERING

SREE VIDYANIKETHAN KARUNYA UNIVERSITY

ENGINEERING COLLEGE KARUNYA NAGAR

A.RANGAMPET, TIRUPATI COIMBATORE

PIN – 517 102 PIN - 641114

THOTA DOONDI SHANKAR NARAYANA

II B.Tech

MECHANICAL ENGINEERING

SREE VIDYANIKETHAN

ENGINEERING COLLEGE

A.RANGAMPET, TIRUPATI

PIN – 517 102

Acknowledgements

First and foremost we would like to thank “FORD INDIA PRIVATE LIMITED”, Chennai Plant for giving

us this Great Opportunity to have carried out this Internship in their Reputed Plant.

We wish to take this opportunity to extend our heartfelt gratitude to our Internship mentor

Ms. Chitra G , Training Master for her constant support in helping us to accomplish the Internship

from initial stages till the end.

We would like to humbly thank the Team Leaders Mr. Karthikeyan (Under Body), Mr. Mathan (Side

Body), Mr. Murali (Framing), Mr. Raj Kumar, Mr. Vijaya Kumaran (Closures), Mr. Chandrasegaran

(Main Line), Mr. Karuppaswamy, Mr. Vadivel (Metal Finish) and all the people for their help in

making us more comfortable at this friendly environment and their valuable inputs about the

machines and layouts in detail which was very useful to complete the Internship.

We would also like to thank Mr. Basha A and Ms. Yogeetha, Human Resources – Learning &

Development, for giving us this privileged opportunity to undertake our Internship in FORD PLANT

(Vehicle Assembly Plant), Chennai.

Finally, we would like to thank our respective college, for giving us this opportunity to undertake our

Internship.

About FORD

The Ford Motor Company (commonly referred to simply as Ford) is

an American multinational automaker headquartered in Dearborn, Michigan, a suburb of Detroit. It
was founded by Henry Ford and incorporated on June 16, 1903. The company sells automobiles and
commercial vehicles under the Ford brand and most luxury cars under the Lincoln brand. Ford also
owns Brazilian SUV manufacturer, Troller, and Australian performance car manufacturer FPV. In the
past it has also produced tractors and automotive components. Ford owns a 2.1% stake in Mazda of
Japan, an 8% stake in Aston Martin of the United Kingdom, and a 49% stake in Jiangling of China. It
also has a number of joint-ventures, one in China (Changan Ford Mazda), one in Taiwan (Ford Lio
Ho), one in Thailand (AutoAlliance Thailand), one in Turkey (Ford Otosan), and one in Russia (Ford
Sollers). It is listed on the New York Stock Exchange and is controlled by the Ford family, although
they have minority ownership.

Ford introduced methods for large-scale manufacturing of cars and large-scale management of an
industrial workforce using elaborately engineered manufacturing sequences typified by
moving assembly lines; by 1914 these methods were known around the world as Fordism. Ford's
former UK subsidiaries Jaguar and Land Rover, acquired in 1989 and 2000 respectively, were sold
to Tata Motors in March 2008. Ford owned the Swedish automaker Volvo from 1999 to 2010. In
2011, Ford discontinued the Mercury brand, under which it had marketed entry-level luxury cars in
the United States, Canada, Mexico, and the Middle East since 1938.

During the financial crisis at the beginning of the 21st century, it was close to bankruptcy, but it has
since returned to profitability.

Ford is the second-largest U.S.-based automaker (preceded by General Motors) and the fifth-
largest in the world based on 2010 vehicle sales. At the end of 2010, Ford was the fifth largest
automaker in Europe. Ford is the eighth-ranked overall American-based company in the
2010 Fortune 500 list, based on global revenues in 2009 of $118.3 billion. In 2008, Ford produced
5.532 million automobiles and employed about 213,000 employees at around 90 plants and facilities
worldwide.

The company went public in 1956 but the Ford family, through special Class B shares, still retain 40
percent voting rights.

History

Henry Ford
20th century
Henry Ford's first attempt at a car company under his own name was the Henry Ford Company on
November 3, 1901, which became the Cadillac Motor Company on August 22, 1902, after Ford left
with the rights to his name. The Ford Motor Company was launched in a converted factory in 1903
with $28,000 in cash from twelve investors, most notably John and Horace Dodge (who would later
found their own car company). During its early years, the company produced just a few cars a day at
its factory on Mack Avenue and later its factory on Piquette Avenue in Detroit,Michigan. Groups of
two or three men worked on each car, assembling it from parts made mostly by supplier companies
contracting for Ford. Within a decade the company would lead the world in the expansion and
refinement of the assembly line concept; and Ford soon brought much of the part production in-
house in a vertical integration that seemed a better path for the era.

Henry Ford was 39 years old when he founded the Ford Motor Company, which would go on to
become one of the world's largest and most profitable companies. As one of the largest family-
controlled companies in the world, the Ford Motor Company has been in continuous family control
for over 100 years.

After the first gasoline powered automobile was created in the year 1885 by German inventor Carl
Benz (Benz Patent-Motorwagen), more efficient production methods were needed to make the
automobile affordable for the middle-class; which Ford contributed to, for instance by introducing
the first moving assembly line in 1913 at its factory in Highland Park.

Between 1903 and 1908 Ford produced the Models A, B, C, F, K, N, R, and S, most of which sold in
the hundreds or few thousands a year. In 1908 Ford introduced the mass-produced Model T, which
would sell in the millions. In 1927, Ford replaced the T with the Model A, the first car with safety
glass in the windshield.[11] Ford launched the first low priced V8 engine powered car in 1932.

In an attempt to compete with General Motors' mid-priced Pontiac, Oldsmobile and Buick, Ford
created the Mercury in 1939 as a higher-priced companion car to Ford. Henry Ford purchased the
Lincoln Motor Company in 1922, in order to compete with such brands as Cadillac and Packard for
the luxury segment of the automobile market.

The creation of a scientific laboratory in Dearborn, Michigan in 1951, doing unfettered basic
research, led to Ford's unlikely involvement insuperconductivity research. In 1964 Ford Research
Labs made a key breakthrough with the invention of a superconducting quantum interference device
or SQUID.

Ford India

Ford manufactures and exports vehicles and engines made at its integrated manufacturing facilities
in Chennai, Tamil Nadu and Sanand, Gujarat.

Since its entry in India in 1995, Ford has invested more than US$ 2 billion to expand its
manufacturing facilities and sales & service footprint to meet demand in one of the world's fastest-
growing auto markets. Ford India’s integrated manufacturing facility at Maraimalai Nagar, near
Chennai, produces its award-winning range of products including the Ford EcoSport and Ford
Endeavour.

As part of its overall commitment, Ford inaugurated its US$ 1 billion state-of-the-art integrated
manufacturing facility in Sanand, Gujarat in March 2015. With Sanand being operational, Ford India
has doubled its annual installed manufacturing capacity to 610,000 engines and 440,000 vehicles.
The sub-four-metre compact sedan, Ford Figo Aspire, became the first car to roll out from the new
Ford Sanand plant. The plant also manufactures new Figo hatchback.

Ford’s biggest-ever product line-up in India today offers a vehicle to suit the needs of nearly every
consumer. In 2016, Ford has also given Indian consumers their first opportunity to own the iconic
Ford Mustang. Debuting ahead of the Delhi Auto Expo 2016 and set to hit Indian showrooms later
this year, the new Mustang is all set to bring the world-class performance and refinement of Ford’s
iconic pony car to India’s roads.

As part of its strategy to Make in India for India and the World, Ford continues to strengthen India as
a center of excellence for small cars and low displacement engines. The company has embarked on
an accelerated export strategy and presently, exports Figo, Aspire, and EcoSport to over 40 markets
around the world.

Along with introducing new products, Ford continues to grow closer to customers with the
continued expansion of its nationwide dealership network as well as world-class after-sales offerings.
Presently, Ford has more than 376 sales and service outlets in 209 cities across India. To enhance
affordability and accessibility, Ford has introduced many pioneering initiatives that reduce the cost
of ownership including the Sub-assembly of parts, Pan-India Roadside Assistance, and Mobile Service
Support. To ensure total transparency in service costs, Ford also introduced a unique Service Price
Promise, which allows customers to calculate the vehicles’ periodic maintenance costs even before
booking the service at the dealership. 

Ensuring customer convenience, Ford has expanded the availability of Ford Genuine Parts with the
appointment of distributors in Maharashtra, Goa, Karnataka, Kerala, Delhi, Tamil Nadu, AP, and
Telangana.

Ford’s presence in India includes Ford Credit India, which started dealer wholesale inventory and
retail financing in 2015 as a non-banking financial company. With five decades of global experience,
Ford Credit’s operations span in as many as 100 countries where it has emerged as a preferred
automotive financier for both Ford customers as well as dealers.

Ford Credit is known for its reliable and transparent loan products at competitive rates, flexible
terms, and outstanding customer service.

Continuing to generate employment and help the economy, Ford’s operations currently employ
more than 14,000 hard-working, dedicated men and women across its operations in India which also
include Global Business Services, with offices in Chennai, New Delhi, and Coimbatore.

Registered as Ford Motor Pvt Ltd. (FMPL) as a legal entity, Global Business Services provide
innovative solutions to nearly every Ford locations around the world in areas of Information
Technology, Product Engineering, Finance and Accounting, Automotive Financing, Material, Planning
& Logistics, Marketing Sales and Service, Analytics, and Purchasing.

Driving innovation from India, Ford recently announced plans to build a new global engineering and
technology center in Chennai. Besides the establishment of a global engineering and technology
center, the new Ford campus spread across 28 acres will host operations of Ford Global Business
Services in areas of IT, Product Engineering, Finance and Accounting, Data Analytics, Manufacturing
among others.

Ford’s commitment to India is not just business centric. At the heart of our business plans are people
and communities. Going further with its Better World philosophy, Ford India in association with Ford
Motor Company Fund announced ‘Operation Better World,' with the endeavour to address issues
related to Education, Sustainability and Auto Safety around communities where it operates.

CHENNAI FORD PLANT

It was 1998 when Ford started a new branch in Chennai i.e., Ford Chennai Vehicle Assembly Plant.

The first production of this plant was FORD IKON which successfully happened in the year 2000.

In next few years it started producing other model like FORD FIESTA.

In 2004, it included FORD ENDEAVOUR in its production.

This Plant also included other models like FORD FIGO, FORD ECOSPORT, FORD ENDEAVOUR (New

model) in its manufacturing and production units.

In 2010, FORD ECOSPORT took the lead and other few models are stopped.

At present, the Plant has two models in its manufacturing and production units.

 FORD ECOSPORT

 FORD ENDEAVOUR (New Model)

In the year 2008, Engine Plant was established.

Plant Overview
The Plant comprises of various shop floors for complete outcome of any Car.

They are

 Body Shop

 Paint Shop

 TCF

Finally, Car undergoes various track tests, water test etc., before it gets into the Market.

BODY CONSTRUCTION
 Car Body gets shape. It is also called as Body Shop.

 It comprises of various zones.

 UNDER BODY

The Bottom part of Car Body is called Under Body. It includes assembly of Engine

Compartment, Front Floor and Rear Floor which is carried out in various stages at several

stations. It is explained in detail in following pages.

 SIDE BODY
 Sides of Car Body which are assembled to the Under Body are called Body Sides (LH & RH).

Making of LH and RH Body Sides takes place in this zone in various stages at several stations.

It is explained in detail in following pages.

 FRAMING

Assembling of Body Sides (LH & RH) and Roof to the Under Body takes place in this zone in

various stages at several stations. It is explained in detail in following pages.

 CLOSURES

Front and Rear Doors (LH & RH) , Hood and Swing Gate constitute Closures. Making of Front

and Rear Doors (LH & RH) , Hood and Swing Gate is carried out in this zone in various stages

at several stations. It is explained in detail in following pages.

 MAIN LINE

Assembling of Closures to the Framed Body part takes place in this zone in various stages at

several stations. It is explained in detail in following pages.

 METAL FINISHING

Checking of Defects by inspection and their Rectification by rework, if any are present is

carried out in this zone in various stages at several stations. It is explained in detail in

following pages.

Operations involved in BODY SHOP

 Blanking

 Stamping

 Sealer application

 Spot Welding
  Stud Welding

 MIG Welding

 Clinching

 Hemming

 Surface Grinding

 Fixing (Bolts and Nuts)

 Visual Checking

 Rectification of Defects

Under Body>>>
 Comprises of Engine Compartment, Front Floor and Rear Floor.

 Engine Compartment
Apron, Front Bumper and Dash panel constitute Engine compartment.

No. of stations : 7 (Manual - 4) (Auto - 3)

Dash Panel :
One Stamped dash part is applied sealer and above this another sealer applied stamped
dash part and spot welded. Child parts such as Brake booster, Cross member and Cowl top etc., are
added and then spot welded. Dash panel is now ready for further assembly. All the above process is
done in a total of 9 stations.

Manual

Station 1: Housing and Front rail(LH & RH) together constituting ‘Apron’ are attached with the help

of spot welding and thus Aprons (LH & RH) are ready for further assembly.

Station 2: Front Bumper is attached to LH and RH aprons by spot welding.

Station 3: Dash panel takes its place in above assembly and spot welded.

Station 4: Re spot welding takes place.

Auto

Station 5: A pair of robots carries out re spot welding.

Station 6: A pair of robots carries out re spot welding.

Station 7: A pair of robots carries out re spot welding.

Now the Engine Compartment is ready for further Assembly.

 Rear Floor
It is the Floor part located at rear end.

No. of stations : 12

Sub-assembly - 5 stations

Station 1: Rear floor part is attached to the stamped part and spot welded.

Station 2: Re spot welding is carried out.

Station 3: Child parts are attached and spot welded.

Station 4: 4 cargo hooks are fixed with the help of bolts.

Station 5: Re spot welding is carried out.

Main Line - 4 stations

Station 1: Side members are attached to the above assembly and spot welded.

Station 2: Cross ring is added and spot welded.

Station 3: Back panel takes its place and spot welded.

Station 4: Re spot welding takes place.

In next 3 stations, 3 pairs of robots carries out re spot welding.

 Now Rear Floor is ready for further Assembly.

 Front Floor
It is the floor part located at the front end.

No. of stations : 7

Manual - 5 stations

Station 1: Front part is attached to the stamped part and spot welded.

Station 2: Cross member is added and spot welded.

Station 3: Seat hooks are fixed with the help of bolts.

Station 4: Re spot welding takes place.

Station 5: Child parts are added and spot welded.

Auto - 2 stations

In these 2 stations, 2 pairs of robots carries out re spot welding.

Now the Front Floor is ready for further Assembly.

 Geo Station
Engine Compartment, Front Floor and Rear Floor are brought into single station from three
different lines and assembled with the help of automated spot welding. Now Under Body is
ready.

With the help of Electro Mono System, Under Body is sent to lifter which lifts and takes it to
the Under Body main line. This under Body main line consists of 7 pairs of robots which
carries out re spot welding.

After the above process, Under Body is fitted to the ‘Ski bar’ to facilitate the shuttle
movement throughout until the Wheel assembly.

Side Body>>>
Comprises of body sides (LH & RH) which are to be framed with Under body to which roof
and closures are assembled.

LH:
No. of stations : 11 (BS – Body Side) (SA – Side Assembly)

 Front Ring
Station 1: BS 03 : B-pillar, A-pillar, rocker and roof rail are assembled and spot welded.

Station 2: BS 05 : T-part is attached to the above assembly and spot welded.

Station 3: BS 07 : Cowl top is placed on top of the assembly and spot welded. Re spot welding also

takes place. Front Ring is ready for side assembly.

 Rear Ring
Station 4: BS 10 : To the stamped Wheel arch housing, wheel arch inner is attached with the help of

sealer and spot welded.

Station 5: BS 20 : The above assembly is placed on D-pillar and spot welded. Further C-pillar is

added and spot welded. Re spot welding is done in 4 stations further.

Rear Ring is ready for side assembly.

 Side Assembly
Station 6: SA 10 : To the stamped outer periphery of body side, front ring is assembled.

Spot welding is done further.

Station 7: SA 20 : Additional small parts are welded to the above assembly.

Station 8: SA 30 : Rear ring is welded to the above assembly.

Now manual re spot welding takes place in 3 stations.

Station 9: SA 40 : Auto re spot welding takes place with the help of 4 pairs of robots.

Station 10: SA 50 : Clinching process is carried out. It is done with Electro Mono System.

Station 11: SA 60 : Buy-off takes the role.

Now the Body Side (LH) is ready for further assembly.

RH:
No. of stations : 11 (BS – Body Side) (SA – Side Assembly)

 Front Ring
Station 1: BS 03 : B-pillar, A-pillar, rocker and roof rail are assembled and spot welded.

Station 2: BS 05 : T-part is attached to the above assembly and spot welded.

Station 3: BS 07 : Cowl top is placed on top of the assembly and spot welded. Re spot welding also
 takes place. Front Ring is ready for side assembly.

 Rear Ring
Station 4: BS 10 : To the stamped Wheel arch housing, wheel arch inner is attached with the help of

sealer and spot welded.

Station 5: BS 20 : The above assembly is placed on D-pillar and spot welded. Further C-pillar is

added and spot welded. Re spot welding is done in 4 stations further.

Rear Ring is ready for side assembly.

 Side Assembly
Station 6: SA 10 : To the stamped outer periphery of body side, front ring is assembled.

Spot welding is done further.

Station 7: SA 20 : Additional small parts are welded to the above assembly.

Station 8: SA 30 : Rear ring is welded to the above assembly.

Now manual re spot welding takes place in 3 stations.

Station 9: SA 40 : Auto re spot welding takes place with the help of 4 pairs of robots.

Station 10: SA 50 : Clinching process is carried out. It is done with Electro Mono System.

Station 11: SA 60 : Buy-off takes the role.

Now the Body Side (RH) is ready for further assembly.

FRAMING>>>
Operation follows

 Underbody , Body side (L.H & R.H) and Roof Assembly.

No. of Stations-13

Manual - 4 Auto - 9

Operation (MB-Main Buck)

  Manual Stations

Station 1: MB 05 : Brings Underbody ready for Assembly.

Station 2: MB 10 : Joining body sides to Underbody – Tabbing Process.

Station 3: MB 20 : To the above assembly,4 ‘anti flutter sealer’ applied bows namely

Front , Rear and 2 Middle Bows are attached to facilitate roof assembly.

Also Cowl Part is attached below wind shield fitting area – Tabbing Process.

Station 4: MB 30 : Idle Station (No work will be done).

 Auto Stations

Station 5: MB 40 : Gripper holds the above assembly to maintain Dimensional Accuracy

(±5% tolerance) and welded for Key Spots to maintain that Dimensional

Accuracy throughout.

Station 6: MB 50 : Re spot welding above assembly. Here Robot changes equipment for ease of

Welding.

Station 7: MB 60 : Gripper helps in Roof fixing and further spot welded.

Station 8: MB 70 : Back panel at bottom , 2 small parts under cowl part are attached through

automation by Shot Guns and spot welded.

Station 9: MB 80 : Re spot welding takes place.

Station 10: MB 90 : Re spot welding takes place.

Station 11: MB 100 : Re spot welding takes place.

Station 12: MB 110 : Re spot welding takes place.

Station 13: Vertical Drop Lifter : Lifts the assembly for visual checkpoint.

And further brought down for Re spot welding(2 manual -> 2 auto -> 2 manual).

 Framing is completed and the ‘Framed Assembly’ boards another line for further processing.

CLOSURES>>>
 Closure includes making of front and rear doors , hood and swing gate.

 Doors - LH & RH

Front Door
 LH & RH

Rear Door

LH:
 Front Door(FD)

Consists of 2 parts namely Inner and Outer parts.

No. of Stations : 5

Station 1: FD 10 : Atbelt , Upper and lower Hinge supports are attached to the Inner part . Sealer is

applied in attachment of Atbelt . Spot welding is done further .

No. of Spots -- 12.

Station 2: FD 15 : Check arm , C-channel are attached . Sealer is applied during attachment. Spot

Welding is done further.

No. of Spots -- 12.

Station 3: FD 20 : A-channel , B-channel are attached . Spot welding is done further.

No. of Spots -- 13.

Station 4: FD 22 : Re spot welding is carried out.

No. of Spots -- 15.

Station 5: FD 25 : Outer belt and Strainer are attached . Spot welding is done further.

No. of Spots -- 15.

The Outer part and Inner part are assembled with the help of automation . Sealer is applied to
the outer part in 2 steps . First to outline of window with less thickness and then in the middle with
more thickness . This outer part is supported by Robotic holder and then the inner part is brought
and assembled .

Next operation is ‘Hemming’ an operation similar to Clinching . Hemming is carried out in 2

steps . First hemming includes door outline and second includes window periphery . Spot welding is
done further (5 Spots - Auto). Upper and Lower Hinges are attached to their supports . Then Visual
Checking takes place and further Grinded if needed . Thus the LH Front Door is ready.

 Rear Door(RD)
 Consists of 2 parts namely Inner and Outer parts.

No. of Stations : 4

Station 1: RD 10 : B-channel , Upper and lower Hinge supports are attached to the Inner part .

Sealer is applied in attachment of channel . Spot welding is done further .

No. of Spots -- 9.

Station 2: RD 12 : Check arm , C-channel are attached . Sealer is applied during attachment. Spot

Welding is done further.

No. of Spots -- 13.

Station 3: RD 15 : A-channel , Strainer are attached . Spot welding is done further.

No. of Spots -- 17.

Station 4: RD 20 : Outer belt and small Strainer are attached . Spot welding is done further.

No. of Spots -- 12.

The Outer part and Inner part are assembled with the help of automation . Sealer is applied to
the outer part in 2 steps . First to outline of window with less thickness and then in the middle with
more thickness . This outer part is supported by Robotic holder and then the inner part is brought
and assembled .

Next operation is ‘Hemming’ an operation similar to Clinching . Hemming is carried out in 2

steps . First hemming includes door outline and second includes window periphery . Spot welding is
done further (5 Spots - Auto). Upper and Lower Hinges are attached to their supports . Then Visual
Checking takes place and further Grinded if needed . Thus the LH Rear Door is ready.

RH:
 Front Door(FD)

Consists of 2 parts namely Inner and Outer parts.

No. of Stations : 5

Station 1: FD 10 : Atbelt , Upper and lower Hinge supports are attached to the Inner part . Sealer is

applied in attachment of Atbelt . Spot welding is done further .

No. of Spots -- 12.

Station 2: FD 15 : Check arm , C-channel are attached . Sealer is applied during attachment. Spot

Welding is done further.

 No. of Spots -- 12.

Station 3: FD 20 : A-channel , B-channel are attached . Spot welding is done further.

No. of Spots -- 13.

Station 4: FD 22 : Re spot welding is carried out.

No. of Spots -- 15.

Station 5: FD 25 : Outer belt and Strainer are attached . Spot welding is done further.

No. of Spots -- 15.

The Outer part and Inner part are assembled with the help of automation . Sealer is applied to
the outer part in 2 steps . First to outline of window with less thickness and then in the middle with
more thickness . This outer part is supported by Robotic holder and then the inner part is brought
and assembled .

Next operation is ‘Hemming’ an operation similar to Clinching . Hemming is carried out in 2

steps . First hemming includes door outline and second includes window periphery . Spot welding is
done further (5 Spots - Auto). Upper and Lower Hinges are attached to their supports . Then Visual
Checking takes place and further Grinded if needed . Thus the RH Front Door is ready.

 Rear Door(RD)

Consists of 2 parts namely Inner and Outer parts.

No. of Stations : 4

Station 1: RD 10 : B-channel , Upper and lower Hinge supports are attached to the Inner part .

Sealer is applied in attachment of channel . Spot welding is done further .

No. of Spots -- 9.

Station 2: RD 12 : Check arm , C-channel are attached . Sealer is applied during attachment. Spot

Welding is done further.

No. of Spots -- 13.

Station 3: RD 15 : A-channel , Strainer are attached . Spot welding is done further.

No. of Spots -- 17.

Station 4: RD 20 : Outer belt and small Strainer are attached . Spot welding is done further.

No. of Spots -- 12.

 The Outer part and Inner part are assembled with the help of automation . Sealer is applied to
the outer part in 2 steps . First to outline of window with less thickness and then in the middle with
more thickness . This outer part is supported by Robotic holder and then the inner part is brought
and assembled .

Next operation is ‘Hemming’ an operation similar to Clinching . Hemming is carried out in 2

steps . First hemming includes door outline and second includes window periphery . Spot welding is
done further (5 Spots - Auto). Upper and Lower Hinges are attached to their supports . Then Visual
Checking takes place and further Grinded if needed . Thus the RH Rear Door is ready.

 Hood
It consists of 2 parts namely Inner and Outer parts.

Inner part - 2 stations (Fixtures)

Station 1: 5G010 : To the stamped inner panel, Striker, Upper and Lower child parts are added and

spot welded.

No. of spots – 12

Station 2: 5G015 : To the above assembly, 2 hinge parts are added and spot welded.

No. of spots – 12

Now Hood inner part is ready for further assembly.

Assembly - 5 stations (Robot shell)

 One robot holds the inner part and applies sealer to it.
 Another robot holds the outer part and applies adhesive sealer to the inner side.
 Both the parts are brought to clinching bed 1 where their assembling and preclinching is done.
 It is transferred to clinching bed 2 where full clinching is done.
 This is transferred to the unloading bed.
From the unloading bed, it is moved to buy off table where checking of surface defects
takes place and rectified if any are present.
Now Hood is ready for further assembly.

 Swing Gate
It consists of 2 parts namely Inner and Outer parts.

Inner part - 6 stations (fixtures)

Station 1: 5F010 : To the stamped inner panel, upper, lower hinges and latch are added and spot

welded.
 No. of spots – 17

Station 2: 5F015 : To the above assembly, stud part or pivot bracket is added and spot welded.

No. of spots – 9

Station 3: 5F020 : Spare wheel upper and lower support brackets are added to the above assembly

and spot welded.

No. of spots – 21

Station 4: 5F028 : Re spot welding takes place.

No. of spots – 17

Station 5: 5F025 : Re spot welding takes place.

No. of spots – 18

Station 6: 5F029 : Re spot welding takes place.

No. of spots – 13

Assembly - 5 stations (Robot shell)

 One robot holds the inner part and applies sealer to it.
 Another robot holds the outer part and applies adhesive sealer to the inner side.
 Both the parts are brought to clinching bed 1 where their assembling and preclinching is done.
 It is transferred to clinching bed 2 where full clinching is done.
 Now with the help of pedestrial welding machine, final spot welding(21 spots) is done.
 This is transferred to the unloading bed where stud welding(1 stud) takes place.
 5F060 : Upper and lower hinges are clamped and fixed in this station.
From the unloading bed, it is moved to buy off table where checking of surface defects
takes place and rectified if any are present.
Now Swing Gate is ready for further assembly.

Main Line>>>
Closures i.e., Front and Rear doors(LH & RH),Hood and Swing Gate along with fenders are
assembled to the Framed Body. The Process includes MIG Welding, Fitting, Adjusting and Checking.

No. of Stations : 17 (ML – Main Line)

Station 1: ML 00 : Checking for Burrs, Dents etc., and their removal takes place.

Station 2: ML 10 : MIG Welding is carried out. Where Spot Welding is not possible there MIG

Welding takes the role.

Station 3: ML 20 : Hood hinge fitment with the help of Bolts. Back panel is Grinded if needed.

Station 4: ML 30 : Rear doors (LH & RH) fitment is carried out with the help of Bolts.

Station 5: ML 40 : Rear doors’ adjustment takes the role with the help of Hammer and Chisel.

Station 6: ML 50 : Front doors (LH & RH) fitment is carried out with the help of Bolts.

Station 7: ML 60 : Front doors’ adjustment takes the role with the help of Hammer and Chisel.

Station 8: ML 70 : Fenders (LH & RH) are loaded.

Station 9: ML 80 : Fenders’ fitment takes place with the help of Bolts.

Station 10: ML 90 : Fenders’ adjustment takes place to maintain distance (1.9 to 4.9mm) between

front door and fender.

Station 11: ML 100 : Hood fitting is done to hood hinges with the help of hood Jig and Bolts.

Station 12: ML 110 : Hood adjustment and Swing Gate fixing with Bolts is carried out. Slave tool

helps in hood adjustment.

Station 13: ML 120 : Swing Gate adjustment is done.

Station 14: ML 130 : Buy-off (Checking) takes the role. Checking of front, rear doors and fenders is

carried out.

Station 15: ML 140 : Empty station. Nothing will be done.

Station 16: ML 150 : Empty station. Nothing will be done.

Station 17: ML 160 : Final buy-off. Final checking of closures is carried out.

Metal Finishing>>>
This is the final zone in the Body Shop where outer and inner surface defects such as dents,
dings, weld defects, damage etc., are checked and rectified if any are present.

Metal Finishing follows 6 stages in which Inspection (Visual , Touch & Feel) and Rework are
carried out.

Stage 1: Outer periphery (Fender, Front & Rear Doors, Quarter Rail) of Lower Deck of body (LH & RH)

is inspected.

Stage 2: Inner periphery of Lower Deck of body (LH & RH) and some part of Swing Gate is inspected.

Stage 3: Upper Deck of body(Window part, Roof, Hood, Swing Gate, Header) is inspected.

Stage 4: Rework starts from here. It includes rectifying of defects with the help of Dent puller,
 Buffing machine, Flat Rough File, Hammer, Belt Grinding machine, Chisel, Punch and hook.

Stage 5: It is the Validation stage. It includes checking of minor and major defects and validates

Whether it is ‘OK’ or ‘NOT OK’. If ‘OK’ then it is sent to Body Bank. Otherwise to Offline

Conveyer.

Stage 6: VIN (Vehicle Identification Number) tracking is carried out manually with the help of scanner

and then noted in a register.

After stage 6, body goes to Body Bank if it is ‘OK’ or it goes to Offline Conveyer if it is ‘NOT OK’.

Now “BODY CONSTRUCTION” is completed. Then it follows further processing like Paint and
TCF.