Basic Manufacturing Process

MODULE 1:
OVERVIEW OVERALL VEHICLE

MANUFACTRING PROCESS
1) INTRODUCTION/
PENGENALAN
1) INTRODUCTION/PENGENALAN
OBJECTIVE :
The objective of this overview of Vehicle Manufacturing Process is to give student
the basic technical knowledge on overall main basic car manufacturing process
starting form car design, tooling development, component manufacturing and
assembly to a complete car.
BACKGROUND :
To make a student interested in the automotive education and carrier in automotive
industry, the student must first understand the overall car manufacturing process
with customized training material. The training material has to be developed and
presented by a team of long experienced industry personal. On technical matter,
presentation with graphic and animation will ensure better communication toward
better and faster understanding.
Trainer is motivated to raise awareness in our industry about the coming skilled-
labor shortage and how it has the potential dramatically hinder future sustainability
and growth. He believes that with Malaysian Automotive Institute (MAI) human
capital development programme, Malaysian can secure their future as as
competetive leaders in the automotive industry.
18
Sept ‘11
1410 INA
1270
1100
970
860
760
MAL
647
624 631 639
618
Source: MAA & Gaikindo

MARKET SHARE
2012 2013
EMPLOYMENT IN AUTOMOTIVE INDUSTRY
TENAGA KERJA DI INDUSTRI AUTOMOTIF
SECTOR MANUFACTURING
AFTER MARKET
DIRECT INDIRECT
Employment 180,000 70,000 300,000
Total 250,000 300,00
Total Employment 550,000
MANUFACTURING EMPLOYMENT EMPLOYER

Vehicle Manufacturers (OEM) 60,000 11 companies
Vendors 190,000 550 companies
TOTAL 250,000 561 companies
Source : MITI
DOMESTIC VS IMPORT CBU
TAHUN 2007 2008 2009 2010 2011 2012
DOMESTIC 487,176 548,115 536,905 605,156 600,123 627, 753
IMPORT 25,515 44,897 35,769 68,415 89,897 86,588

NEW CBU
CAGR : 29%
NEW CBU
MARKET
5.2 8.2 6.7 11.3 15.0 13.8
SHARE
(%)
Source : MITI
What is CBU?/APA ITU CBU
CBU – Complete Built Up
A CBU import means a vehicle is completely built out of the country. A CBU import
does not mean that the vehicle is 100% built in its origin country. For example, a
CBU Honda imported to Malaysia can be assembled in other Honda plants in
either Thailand or Indonesia. Most Honda in Malaysia are imported from Thailand
due to the geographical location. The quality of a CBU vehicle very much depends
on the QC (Quality Control) of the plant.
CBU – Complete Built
Up.
Adalah sesebuah kereta
atau kenderaan yang di
buat atau dipasang
sepenuhnya luar dari
Malaysia.
Unloading CBU car

from Ship at Port.
What is CKD?/Apa itu CKD
CKD – Complete Knock Down
A CKD vehicle means a vehicle is assembled locally using all the major parts,
components, and technology imported from the country of its origin. Government
imposed excessively high taxes on CBU vehicles to encourage foreign car
manufacturers to build factories and produce their vehicles in the country. This
would help the country’s economy as well as to increase the employment rates.
This is the reason why we see more and more CKD vehicles available in the
country.
Boxes of part and component Large Stamping

Imported from oversea call CKD box. part in un box
What is SKD?/Apa itu SKD
SKD – Semi Knock Down
SKD stands for semi knockdown vehicle. Component in module assembly
and Body In White (BIW) imported from origin country and assemble to a a
complete car locally. SKD is between CKD and CBU where tax imposed
lower than CBU but higher than CKD.
OEM CATEGORIZATION
ELECTRICAL
4 MILL vendor ( wire 50 INJECTION
(steel harness) vendor (Interior , 41
coil) STAMPING Bumper, lighting)
136 &ASSY vendor
(Body & Chassis) HYUNDAI,
HONDA, KIA,
PROTON TOYOTA, VOLVO
NISSAN Others
PERODUA CKD SKD
STAMPING PAINTING TRIM &

RnD BODY SHOP FINAL SHOP
SHOP SHOP
TOOLING ENGINE &

DEVELOPMENT TRANSMISSIO
CASTING & N SHOP
Vendor MACHINING
Tier 1 = 200 17 OTHER 75
vendor CBU
Tier 2 = 200 (Powertrain)
* OEM = original equipment manufacturers
VENDOR CATEGORIZATION
INTERIOR 41 17 Others
13 BODY IN
6 WHITE
ELECTRICAL 50 75 POWERTRAIN CHASSIS
Manufacturing Process Flow (OEM)
Assembly/Welding of loose stamped body
Stamping of flat metal sheet to form panels to form a full car body (body in white)…
Stamping various car body panels. Body
Metal Body Component vendor Logistic
Paint Painting of Body in White in accordance Trim & Final Fitting of trim & chassis components to
to color choice ordered by customer… (TF) form a complete built automobile…
Minor
Engine &
Metal Cahsis Component vendor Tranmission plant. Repairs
Machining &
Plastic and Rubber component vendor
Assembly of
Sales
Engines
Casting & Machining component vendor OK
(detail next
page)
Manufacturing Process Flow (OEM) - continue CASTING PLANT
PARTS MACH LINE
ASSEMBLY LINE
to TF Shop
to TF Shop
Casting & Machining Component vendor

to TF Shop
PROTON SHAH ALAM
Example of OEM Manufacturing Layout

TRIM &
FINAL ENGINE
MVF BODY
STAMPING RND
Motorpool
Admin Office
30 30
https://www.youtube.com/watch?v=QXOguvLi9Fo
2) NEW MODEL DEVELOPMENT/
PEMBANGUNAN MODEL BARU
NEW MODEL DEVELOPMENT SCHEDULE
2005 2006 2007 2008
P2-110 Program 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3
-30 -30 -29 -28 -27 -26 -25 -24 -23 -22 -21 -20 -19 -18 -17 -16 -15 -14 -13 -12 -11 -10 -9 -8 -7 -6 -5 -4 -3 -2 -1 1
Style theme AT Ext. style Maj. Freeze DQCM

Master Milestone selection selection model fix (Side Outer) (ESO)
Rendering SOP
ALIAS
FULL MODELLING
RENDERING
Style Quick surfacing 18 Months
Exterior approval Ext. fix Int. fix
Development apprccoval
Scale model 1:1 model
Class "A" surfacing
SCALE MODELLING Verification model
Base data check

Engine room package Main body installation drawing
Feasibility study
Typical section
R&D Design PART DRAWING

Mule design
Engineering Production layout Parts drawing
Pre layout (SE) Instruction
Fillet data Fillet data
PROTOTYPE
DCS
DPS
MULE CAR ODB Aero dyna. Pre L/O Production L/O

CAE CAE confirm
Design
Verification Mule car build-up Off-tool prototype build-up
& Mule car test Pilot test
Validation Design master vehicle (interior) PV test
SE DRAWING Homologation
Feasibility review
SE DR 1 DR2
SM 1 SM 2 Drawability / welding gun accessability
Basic plan / Line concept

Plan Standard document
Process plan
RFQ Ordering
Production Production Purchase order
Engineering Preparation Design Casting Manufacturing M/TO Ship L/TO
Equipment preparation - Dies Pilot 5M
Design Manufacturing M/TO Ship Install/TO
TOOLING DEVELOPMENT Equipment preparation - Jig
Pilot
Quality
Screw body
Improvement
CAR DEVELOPMENT COST Investment for any new model with
new platform and existing engine =
RM 600,000,000.00
CAR DEVELOPMENT COST
Investment for any new model with sharing platform and existing engine
estimated RM 400,000,000.00 (save RM200,000,000.00)
PREVE / SUPREMA
R&D Styling development/
Pembangunan R&D Styling
- Concept/Konsep
- Rendering/Lakaran
2005 2006 2007 2008
P2-110 Program 8
-30
9
-30
10 11
-29 -28
12
-27
1
-26
2
-25
3
-24
4
-23
5
-22
6 7
-21 -20
8
-19
9
-18
10
-17
11
-16
12
-15
1
-14
2
-13
3
-12
4
-11
5
-10
18 Months
6
-9
7
-8
8
-7
9
-6
10
-5
11
-4
12
-3
1
-2
2
-1
3
1

Rendering SOP
ALIAS FULL MODELLING
RENDERING
Style Quick surfacing
SCALE MODELLING Class "A" surfacing

Verification model
Base data check

Feasibility study
Typical section
R&D Design Mule design

Engineering PART DRAWING Production layout Parts drawing
DCS
DPS
PROTOTYPE
ODB Aero dyna. Pre L/O Production L/O
Design
MULE CAR CAE CAE confirm

Homologation
SE DRAWING
Feasibility review
SE DR 1 DR2

Process plan
RFQ Ordering
Equipment preparation - Dies
Equipment preparation - Jig
Pilot 5M
Pilot
Quality
Improvement
TOOLING DEVELOPMENT Screw body
DESIGN CONCEPT ( internal space)
The development process had to start from the inside out. The seat, hip points,
interior height and etc were all determined first, only then are the other parts of
the chassis and body designed around it, interior and exterior design of the car.
The designers had to work within these restrictions.
Height
DESIGN CONCEPT (external dimension)
Wheelbase
Track
Length
DESIGN SKETCHING & RENDERING (exterior)
A few sample of Proton

Exora exterior sketches
& rendering.
R&D Styling development
- Scale modelling
2005 2006 2007 2008
P2-110 Program 8
-30
9
-30
10 11
-29 -28
12
-27
1
-26
2
-25
3
-24
4
-23
5
-22
6 7
-21 -20
8
-19
9
-18
10
-17
11
-16
12
-15
1
-14
2
-13
3
-12
4
-11
5
-10
186 Months
-9
7
-8
8
-7
9
-6
10
-5
11
-4
12
-3
1
-2
2
-1
3
1

Rendering
FULL MODELLING SOP
ALIAS
RENDERING
Class "A" surfacing
Verification model
SCALE MODELLING
Base data check
Feasibility study
Typical section
Design
PART DRAWING
R&D Mule design
DCS
DPS
PROTOTYPE
MULE CAR
CAE CAE confirm
Design

Feasibility review
SE DR 1 DR2

Process plan
RFQ Ordering
Engineering Preparation
Pilot 5M
Design Casting Manufacturing M/TO Ship L/TO
Pilot
Quality
Screw body
Improvement
SCALE CLAY MODELLING (half car)
SCALE CLAY MODELLING (whole car)
SCALE CLAY MODELLING (whole car)
SCALE CLAY MODELLING APPROVAL
R&D Styling development
- Full modelling
- 3D surface scanning
P2-110 Program 8 9
2005
10 11 12 1 2 3 4 5 6
2006
7 8 9 10 11 12 1 2 3 4 5 18
6 Months
2007
7 8 9 10 11 12 1
2008
2 3
-30 -30 -29 -28 -27 -26 -25 -24 -23 -22 -21 -20 -19 -18 -17 -16 -15 -14 -13 -12 -11 -10 -9 -8 -7 -6 -5 -4 -3 -2 -1 1

Rendering FULL MODELLING SOP

ALIAS
RENDERING
SCALE MODELLING Class "A" surfacing
Verification model
Base data check

Feasibility study
Typical section

PART DRAWING Fillet data Fillet data
DCS
DPS
PROTOTYPE
MULE CAR CAE CAE confirm
Design

Feasibility review
SE DR 1 DR2

Process plan
RFQ Ordering
Pilot
Quality TOOLING DEVELOPMENT Screw body
Improvement
FULL SCALE CLAY MODELLING
INTERIOR CLAY MODELLING
3D SURFACE SCANING
RND design engineering
- Part drawing
2005 2006 2007 2008
P2-110 Program 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3
-30 -30 -29 -28 -27 -26 -25 -24 -23 -22 -21 -20 -19 -18 -17 -16 -15 -14 -13 -12 -11 -10 -9 -8 -7 -6 -5 -4 -3 -2 -1 1
Style theme AT Ext. style Maj. Freeze 18 DQCM

Months
Rendering SOP
ALIAS FULL MODELLING
RENDERING
Class "A" surfacing
Base data check

Feasibility study
Typical section

Engineering PART DRAWING Production layout Parts drawing
DCS
DPS

PROTOTYPE
CAE CAE confirm
Design

Homologation
SE DRAWING
Feasibility review
SE DR 1 DR2

Process plan
RFQ Ordering
Pilot 5M
Pilot
Quality
Screw body
Improvement
PART DRAWING
SIMULTENOUS ENGINEERING (SE)
R&D design verification
& validation
- Mule car
2005 2006 2007 2008
P2-110 Program 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3
-30 -30 -29 -28 -27 -26 -25 -24 -23 -22 -21 -20 -19 -18 -17 -16 -15 -14 -13 -12 -11 -10 -9 -8 -7 -6 -5 -4 -3 -2 -1 1

Rendering SOP
FULL MODELLING
18 Months
ALIAS
RENDERING
Class "A" surfacing
Base data check

Feasibility study
Typical section

Mule design
DCS
DPS

CAE CAE confirm PROTOTYPE
Design

Homologation
SE DRAWING
Feasibility review
SE DR 1 DR2

Process plan
RFQ Ordering
Pilot 5M
TOOLING DEVELOPMENT
Pilot
Quality
Screw body
Improvement
MULE CAR BUILD UP.
A development mule or a test mule in the automotive industry is a vehicle
equipped with experimental or prototype components for testing. Automakers
evaluate aspects of vehicles before decided that component match with the body.
Mule cars are drivable, often years ahead of actual productions. They may also
have advanced chassis and powertrain designs from a future vehicle that need to
be tested, but "clothed with the body and interior of some other car about the
same size.
As example Proton use Toyota Wish as a mule car to test the Proton powertrain
and chassis component during Proton Exora design stage.
PRODUCTION ENGINEERING
- Simultaneous Engineering
2005 2006 2007 2008
P2-110 Program 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3
-30 -30 -29 -28 -27 -26 -25 -24 -23 -22 -21 -20 -19 -18 -17 -16 -15 -14 -13 -12 -11 -10 -9 -8 -7 -6 -5 -4 -3 -2 -1 1

Rendering SOP
ALIAS
FULL MODELLING
RENDERING
Development
Scale model apprccoval 1:1 model 18 Months
Class "A" surfacing
Base data check

Feasibility study
Typical section

Mule design
DCS
DPS

CAE CAE confirm
PROTOTYPE
Design
Feasibility review
SE DR 1 DR2

Process plan
RFQ Ordering
Pilot
Quality
Screw body
Improvement
PROCESS SIMULATION
&
DIGITAL MOCK-UP ANALYSIS
PROCESS SIMULATION
WHAT IS DMU ?
Computer-based Product Defination of a real Product (Virtual Product)
DMU can be used :-
• To execute functions, such as to ensure clearance and mountability.

• To make investigation regarding clash, freedom of movement and
ease of assembly (workability).
• To support Virtual Reality.
• To support Visualisation of Packaging and Simulation, such as Ergonomic
Analysis.
DMU’s Goal : Reduce Development TIME,COST and Improve QUALITY

PROCESS SIMULATION Why DMU ?

Integrating V4 and V5 data Kinematics Checks
Realtime Access to Master Installation Process

Vehicle Model data Verification
Vehicle Product Structure and

Engineering BOM Virtual Reality
Clash/Interference Checks Packaging and Ergonomics
Styling Verification Very large scale digital

Full 3D representation
including surfaces thicknesses assembly
Advantages of DMU :- PROCESS SIMULATION
Start
Start Of
Product Development Process
Of Series
(Current)
Project Production
Verification Using Real Objects
Verification using (RP)
Digital Product
Product Development Process

Utilising DMU
RP for testing
purpose
only
Verification
Verification using Digital
Product Using
Real
Objects
t
DMU’s Goal : Reduce Development TIME,COST and Improve QUALITY

SIMULTANEOUS ENGINEERING (SE)
WHAT IS DMU ?
Computer-based Product
Definition of a real Product
(Virtual Product)
DMU can be used :-
• To execute functions, such as to

ensure clearance and mount ability. TOOLS ACCESSIBILITY
• To make investigation regarding ERGONOMIC STUDY
clash, freedom of movement and
ease of assembly (workability).
• To support Virtual Reality.
• To support Visualization of and
Simulation, such as Ergonomic
Analysis. Packaging
CLASH AND INTERFERENCE CHECK
WORKABILITY AND SERVICIBILITY

DMU’s Goal (Digital Mock Up) :Reduce Development TIME,COST and Improve QUALITY
PROCESS SIMULATION
Do the assembly method meet the ergonomic, human comfort and safety standards?
PROCESS SIMULATION
Do the assembly method meet the ergonomic, human comfort and safety standards?
PROCESS SIMULATION
PROCESS SIMULATION
2) Rear muffler loading handling check ※ DPA ( Digital Pre-Assembly )
<DPA Result : NOK>

Clearance : 8.3mm
3) Filling gun access check
<Brake oil filling check> <LLC filling check>
<DPA Result : OK> <DPA Result : OK>

PROCESS SIMULATION
Can my product be serviced?
PROCESS SIMULATION
Division Air tool (Gun type) Battery tool Socket
Maker YOKOTA MAKITA NAC
(3_4) 619,
Model Name y70a y90e 6903VD
(3_8) 314EMP20
Picture
Division Torque Wrench Spanner Torque Wrench
Maker TOHNICHI TOHNICHI
Model Name 1800QSP SP8B
Picture
Division Air tool (Angle type) Hammer Plier
Maker ATLAS COPCO Stanley -
Model Name LTV38 R42-13 5-540 -
Picture
PROCESS SIMULATION
Will the space allocated for the tool access be sufficient?
PROCESS SIMULATION
Do the parts of the assembly fit well together?
PRODUCTION ENGINEERING
- Production preparation on
tooling and equipment.
BODY IN WHITE (BIW) BASIC MODULE POLICY
12 MODULES FOR BIW CAN BE GROUP AS FOLLOW;
OEM VENDOR
IN-HOUSE STAMPING PARTS (6 MODULES) TIER-1 STAMPING PARTS (6 MODULES)
➢ CLOSURE & OUTER SKIN MODULE. ➢ INNER STRUCTURAL.

1. Door. 7. Front End.
2. Tail Gate. 8. Front Deck.
3. Hood. 9. Rear End.
4. Roof. 10.Front Floor.
5. Fender. 11.Rear Floor.
6. Side Outer. 12.Inner Side Structure.
Justification: Justification:
• Outer skin part required minimum • Modular supplying system to ensure efficient
transportation to avoid secondary defect. control and full tier responsibility.
➢ SPECIFIED LARGE & MEDIUM PART ➢ SPECIFIED MEDIUM & SMALL PART.
• Not able to stamp by Tier-1 due to large • Not able to stamp by In House Stamping due
machine size and tonnage requirement. to small machine size, tonnage and
automation requirement.
BODY IN WHITE (BIW) BASIC MODULE POLICY 2) Tail Gate
4) Roof
11) Rear Floor
3) Hood
10) Front Floor
9) Rear End
8) Front Deck 2) Side Outer
12) Inner Side

Structure
7) Front End
OEM – In House 1) Door

5) Fender
Vendor
QUANTITY OF DIES IN EACH MODULE & COST
MODULE (LARGE) (MEDIUM) (SMALL) TOTAL
CLOSURES
25 50 52 127
SIDE STRUCTURE
FRONT& REAR FLOOR

31 48 91 170
FRONT & REAR END
TOTAL 56 98 143 297 parts
MODULE ( LARGE) (MEDIUM) (SMALL) TOTAL
CLOSURES
70 98 94 262
SIDE STRUCTURE
`
FRONT& REAR FLOOR

93 121 224 438
FRONT & REAR END
TOTAL 163 219 318 700 Dies
OEM DIES INVESTMENT : TIER 1 DIES INVESTMENT :

QTY PART : 80 types QTY PART : 160 type
QTY DIES : 300 units QTY DIES : 550 units
DIES COST : 150 millions DIES COST : 80 millions
INTERIOR BASIC MODULE POLICY
QUANTITY OF MOULD IN EACH MODULE & COST
QUANTITY MOULD
PLASTIC PART MOULD COST
(estimated)
BUMPERS 3 3,226,000
SPLASH SHEILD, GARNISHS, MOULDING, UNDER COVER. 5 3,250,000
PILLAR TRIMS 6 2,533,000
INSTRUMENT PANEL AND GLOVE BOX 25 5,583,000
FLOOR TRIMS 3 911,000
DOOR + REAR END TRIMS 12 4,324,000
FLOOR CONSOLE 6 714,000
HEADLINING 1 769,000
FRONT END MODULE (FEM) CARRIER
1 1,625,000
TOTAL 16,459,000
62
MOULD INVESTMENT :
QTY PART : 87 parts
QTY MOULD : 62 units
MOULD COST : 16.5 millions
Start at 14:15
DIES & MOLD DEVELOPMENT LEAD TIME
item month
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Master Milestone
Concept SE Freeze SOP
data PO P1 P2 PP
data data
Draft Body Flow Chart

Simultaneous
Engineering. Formability & Moldability simulation (CAE)
Draft Process Planning (DPP)
Tendering – Tool Maker

& Stamper.
LOI to Dies Maker or Stamper
Dies & Mold making

Dies Design
Pattern - Casting
Buy Ship
Machining-Finishing- Try Line trial
Off
TOOLING
DEVELOPMENT/
PEMBANGUNAN ALATAN & JIG
INJECTION MOULD
There are 4 types of

main Tooling in automotive
1) Stamping Dies
(for metal parts)
2) Injection Mould
(for plastic parts)
1) Welding Assembly Jig
2) Inspection Jig
WELDING ASSEMBLY JIG
INSPECTION JIG
STAMPING DIE
• Tools for producing stamped body PRODUCT
panels in metal or aluminum materials.
• Dies consisting of lower tool & upper
tool in series of MULTIPLE (2~5)
processes, loaded into Mechanical or
Hydraulic presses to produced body
panels.
Lower
Tool
Upper Tool
TOOLING DEVELOPMENT PROCESS
DIES DESIGN MODELLING
PART
PROCESS SELECTION EXTRA SURFACE
DRAWING PLANING (DPP) (CAD)
FORMABILITY
CHECK (CAE)
DIES DRAWING (CAD) – DIES

DESIGN STANDARD
PATTERN CAM DATA
CASTING MACHINING
FINISHING DIES SPOTTING MACHINE (DSP)
TRIAL TRY OUT PRESS (TOP)

TOOLING DESIGN/
REKAAN
ALATAN(ACUAN) & JIG
DRAW DIES BLANK HOLDER SURFACE
During the deep-drawing process, the blank is clamped between die cavity and
blank holder. This clamping area is called extra surface develop by dies designer
from part drawing. The blank holder force is a retracking force required to avoid the
occurrence of wrinkling and crack. While the punch is forming the blank into the die
cavity, blank material flows into die cavity. This effect is called material flow. In
deep-drawing processes, it is important to control material flow in order to get
defect-free components. Main defects in deep-drawing processes are cracks and
sidewall wrinkling..
DRAW DIES BLANK HOLDER SURFACE
CAD MODELLING EXTRA SURFACE
Information of Part Design Information of Forming Simulation
1. Blank Shape & Drawbead Lay-out
- Blank size : 1,590 * 1,600 * 0.6 (mm) = 11.982 kg

- Current Material Utilization : -
A R6
1,600
6
B R3
BEAD “A”
Symmetry
R6
Line 3
R5
1,590
BEAD “B”
A
12
R3
6 R3
BEAD “C”
C
A
1. Maker & Model : PROTON P6-20A

2. Part No. :
3. Part Name : TAILGATE OTR 2. Simulation Conditions Blank Holder surface
- Simulation S/W : LS-DYNA
4. Stage : Skin Feasibility (Extra Surface)
- Blank Holding Force : 140 (Ton) (full model)
5. Part Weight : - - Blank Holding Stroke : 190(mm)
6. Blank Material : SPCD 0.6T - Friction Coefficient : 0.15
7. Press Type : Single Action - Min. Forming Force : 392+ 140 = 532 ton (full model)
8. Master Tool : UPR DIE • Min. Forming Force from simulation is not exact value, but this can be used for
reference data for die design.
CAE FORMABILITY SIMULATION
Binding (190mm UP) 120mm UP
60mm UP 20mm UP
CAE FORMABILITY SIMULATION
5mm UP 3mm UP
1mm UP Bottom
CAE FORMABILITY SIMULATION RESULT
CRACK NECK SAFE
Formability Assessment
Crack Neck
[ Simulation S/W : LS-DYNA ]
Safe
Change part section radius Change draw die condition
2
4 Predicted Defects
1 3
Detail
No. Description of defect The cause of defect Signal
Sheet
1 Crack Sharp part section radius 1

Change part section angle
Crack Sharp part section radius
Change part section radius2 2
Reduce the form depth 3 Crack Sharp part section radius 3
4 Slip Line Unbalanced draw -in Page.10
Change part section radius and angle

Change part shape [Remarks]
CAE THINNING CONTUOR RESULT
Thinning
103 6
52
28
Wrapped blank edge

UNIT : mm
17
84
: Distance between wrapped blank edge and formed blank edge
: Distance between bead center line and formed blank edge
• Simulation uses analytic bead (curve and force), not real geometric bead. Therefore, length to form bead geometry should
be considered to match try-out result
CAE SURFACE QUALITY RESULT
Major Strain Minor Strain Thinning
All skin area have enough major strain.

TOOLING MAKING/
PEMBUATAN
ALATAN(ACUAN)
3D DIES DESIGN (CAD)
Small dies
• made from steel
block
• press tonnage
below 250 tons
Medium dies and

large dies
• made from cast
iron and steel
block.
• press tonnage
300 tons and
above
PATTERN MAKING (POLYSTYRENE)
Cast iron for medium dies and large dies are
made from Evaporative-pattern casting process
that uses a pattern made from a material that will
evaporate when the molten metal is poured into
the molding cavity. The most common
evaporative-pattern material used is polystyrene
foam
From Dies drawing (2D and 3D) Polystyrene

layers are cut and assemble by hand using
special glue, creating each one-of-a-kind
pattern.
The shape surface of the pattern then being
machine with special CNC polystyrene
machine.
COMPLETE PATTERN & FULL MOULD CASTING
Each pattern is visually and

dimensionally inspected before it
is sent to the casting center.
The pattern is hand packed with a

sand and binder mixture that is
controlled by one of five no-bake
sand mixers.
The molten iron flows thru the gating

system and into the mold, evaporating
the pattern as it fills.
COMPLETE PATTERN & FULL MOULD CASTING
Castings are removed after the required

hold time, the empty mold is shook out
and 97% of the sand is reclaimed.
Shotblasting cleans any remaining sand

and coating from the casting.
Castings are inspected and ready for

shipping.
CAM DATA AND MACHINING
CAM data
preparation
Computer-aided manufacturing (CAM) software is use to control machine

tools and related machinery in the manufacturing of of stamping dies.
Experience worker in CAM and experience machinist is required to perform
efficient and quality machining work.
Machinist set
the Dies
Casting and
use CAM
program to
machine.
DIES FINISHING (ASSEMBLY, SPOTTING AND TRIAL)
DIES FINISHING GROUP :
•Assemble Guide Post and Wear Plate.
•Assemble machined steel block into
machine cast iron dies.
• Polishing, Welding, Heat treatment,
Surface treatment, painting.
• Dies trial and adjustment.
Assemble component Surface Matching at Dies Spotting (DSP)

Dies Trial at Try Out Press (TOP)
PROTOTYPE BUILD UP FROM DRAW PANEL.
Pre-production cars are vehicles that allow the automaker to find problems
before a new model goes on sale to the public. Pre-production cars are typically
built in small quantities on a slave production line, or in some cases on the real
production line alongside the current model. Typically the parts used will be off the
production tooling, or at least are intended to represent the final part very closely.
Sometimes the components used to make a pre-production car are a mix between
the prototype models and the mass production versions to come later. All testing
will be performed with these car such as Homologation, Crash Test, Endurance
Test and other test.
PROTOTYPE BUILD UP FROM DRAW PANEL.
A crash test is a form of destructive testing usually performed in order to ensure
safe design standards in crashworthiness and crash compatibility for various
modes of transportation or related systems and components.
• Frontal-impact tests: which is what most people initially think of when asked
about a crash test. These are usually impacts upon a solid concrete wall at a
specified speed
• Side-impact tests: these forms of accidents have a very significant likelihood of
fatality, as cars do not have a significant crumple zone to absorb the impact forces
before an occupant is injured.
• Roll-over tests: which tests a car's ability (specifically the pillars holding the roof)
to support itself in a dynamic impact. More recently dynamic rollover tests have
been proposed as opposed to static crush testing
3)STAMPING
MANUFACTURING
PROCESS/
PROSES PEMBENTUKAN
❖The Difference
Between a Mould and
A Die
PROSES PEMBENTUKAN
Stamping of flat metal sheet to form Body
Stamping panels to form a full car body (body in white)…
various car body panels.
Stamping Body vendor

Logistic
Minor
Engine &
Stamping Chassis vendor Tranmission plant. Repairs
Machining &
Injection vendor Sales
Assembly of
OK
Engines
Casting & Machining vendor (detail next
page)
Stamping Manufacturing Process Flow
Reject
Die Setting
(Send to BLANKING LINE
/ Change
KOPEMA)
NG OK
Cutting
Steel Coil Steel Coil Piling
Inspection Uncoiling Cleaning (Blank /
Receiving Unpacking Shear)
OK
Blank Blank Blank Set

Blank
Sheet Sheet @ Destack Inspection
Storage
Centering Washing Feeder
Die Setting NG
PRESS LINE Reject
/ Change
Draw /
Trimming Piercing Flanging Restrike
Form
Process Process Process Process
Process
Rework/
Palleting
Handwork
OK
Body Part
Assy Storage
Palleting Inspection
NG
Stamping Manufacturing Process Flow
6)STEEL COIL/
GELUNG BAHAN
(komponen badan kereta)
What is Automotive Steel?
Automotive steels can be classified in
several different ways. One is a
metallurgical designation. Second
classification method important to part
designers is strength of the steel. third
classification method presents various
mechanical properties or forming
parameters of different steels, such as
total elongation, work hardening
exponent n, or hole expansion ratio.
Malaysian Automotive Steel Sourcing
JFE &
NSC
38 %
POSCO
44 %
TATA
14 % MEGA
STEEL
4%
DISTRIBUTION BY TYPE OF STEEL
JFE & NSC POSCO TATA MEGA
TYPE OF STEEL
Cold Rolled Steel 18 % 55 % 27 % -
Hot Rolled Steel 21 % 58 % - 21 %
Galvanized Steel 59 % 38 % 3% -
Automotive Steel manufacturing process?
Mining raw from Brazil, Australia & India
Blast Furnace
Hot & Cold Roll

Hot & Cold Roll

Grade tensile distribution.
35Kg HSS 40Kg HSS 45Kg HSS 60Kg HSS Mild Steel
Weight
60
11.9%
%
4.4%
40.0%
23.2%
20.4%
Quantity
216 23
184 29
115
49
Coated and Bare steel distribution.
Weight
Coated Steel Bare Steel
23.7%
76.3%
Quantity 42
358
Coated Steel
Bare Steel
PRESS MACHINE
Hydraulic Press Machine
A hydraulic press is a machine using a hydraulic cylinder to generate
a compressive force. It uses the hydraulic equivalent of a mechanical
lever. The hydraulic press depends on Pascal's principle: the pressure
throughout a closed system is constant. One part of the system is a
piston acting as a pump, with a modest mechanical force acting on a
small cross-sectional area; the other part is a piston with a larger area
which generates a correspondingly large mechanical force. Only small-
diameter tubing (which more easily resists pressure) is needed if the
pump is separated from the press cylinder.
Mechanical Press Machine.

Flywheel energy storage (FES) works by accelerating a rotor
(flywheel) to a very high speed and maintaining the energy in the
system as rotational energy. When energy is extracted from the
system, the flywheel's rotational speed is reduced as a consequence
of the principle of conservation of energy; adding energy to the system
correspondingly results in an increase in the speed of the flywheel.
Most FES systems use electricity to accelerate and decelerate the
flywheel, but devices that directly use mechanical energy are being
developed
TYPE OF MECHANICAL PRESS.
C-FRAME MECHANICAL PRESS
Small tonnage press machine, below 300 tons. Structure is made from thick plate cut
Into C shape. Crank shaft mounted at topside whereas bed sit on bottom side.
Structure simple and cheaper.
H-FRAME MECHANICAL PRESS

Medium and large tonnage, above 300 tons. Crown unit at the top and bed unit at the
bottom connected together with 4 unit of poles (Upright) using 4 units of Tie Rods.
Fixed bolster for 500 tons below and moving bolster above 500 tons
H-FRAME PRESS MACHINE CONSTRUCTION.
MAIN MOTOR CLUTCH & BRAKE
Crown
Assembly Slide
Assembly
Bolster
Assembly
Bed
Assembly Cushion and
Damper
Assembly
PRESS SHOP LAY- OUT AND FLOW
DIES BLANK MATERIAL STORAGE
STORAGE
DIES DIES DIES DIES
500 STORAGE STORAGE STORAGE STORAGE
500 1000 1000 500
BLANKING 500 800 800 500
500 500
500 500
STEEL 500 500

500
500
COIL
STORAGE 500
MEDIUM 1 LARGE 1 LARGE 2 MEDIUM 2
INSPECTION
STAMPING PART STORAGE
JIG
BLANKING LINE
BASIC STAMPING PROCESS
RECEIVING (COIL) AND
BLANKING LINE CUTTING/SHEARING MATERIAL
ACCORDING TO STANDARD
PRESS 1 DRAWING
PRESS 2 TRIMMING THE PART
PRESS 3 PIERCING
PRESS 4 FLANGE / RESTRIKE
PALETING AREA QUALITY CHECK BY QUALITY

AT AUDITOR FOR DEFECTS (BURR,
PALLET TRANSFER HUMP, DENT, SEIZURE ETC)
BLANKING LINE
FEEDER BLANKING
BLANKING PROCESS M ACHINE
WASHING UNIT
DIE
LEVELER ROLLER
COIL LOOP
BLANK
M ATERIAL
BLANKING LINE
128
BLANKING LINE
TYPE OF BLANKING PART
STACKED BLANK PANEL
DRAWING PROCESS (ANIMATION)
PROCESS 1 - DRAW
SLIDE
UPPER DIE
BLANK
HOLDER
PUNCH CUSHION PIN
BOLSTER
PROCESS 2 - TRIM
SLIDE
PAD
SCRAP HOLE
BOLSTER
PROCESS 2 - TRIM
PROCESS 3 - PIERCE/TRIM SLIDE
PAD
PROCESS 4 - FLANGE
STAMPING PROCESS
138
OUT PUT FROM PRESS LINE
Incline
Scrap conveyor 66ft
Scrap Bin
Underground
Scrap conveyor
Scrap material
Stamped part stored
Inside stackable
pallet
STAMPING
PRODUCTION PALLETING
(PACKAGING)/
142
PACKAGING STANDARD OPERATION PROCEDURE (SOP)
143
PACKAGING STANDARD OPERATION PROCEDURE (SOP)
PART ARRANGEMENT IN PALLET
RIGHT : PART WELL-ARRANGED IN WRONG : PART BAD-ARRANGED IN

SUITABLE PALLET UNSUITABLE PALLET
144
4)WELDING
ASSEMBLY PROCESS/
PROSES PEMASANGAN
KIMPALAN
145
Stamping of flat metal sheet to form Body
Stamping panels to form a full car body (body in white)…
various car body panels.
Stamping Body vendor

Logistic
Minor
Engine &
Machining &
Injection vendor Sales
Assembly of
OK
Engines
Casting & Machining vendor (detail next
page)
WELDING ASSEMBLY
From... To
LOOSE STAMPING PART BODY IN WHITE (BIW)
OEM WELDING ASSEMBLY
Components
Supplier (vendor)
Roof
Rear floor panel Bodyside Closures
Underbody complete Main body
Front floor panel Bodyside Closures
Components
COMPONENT MANUFACTURER
Center Pillar
Sub Assembly
Tier 1 and Tier 2 - WELDING SUB-ASSEMBLY FLOW
Center Pillar Sub-Assembly
Tier – 2
(stamping + weld nut)
Tier 1 supply
to OEM follow
Kanban
Tier – 1
(stamping + weldnut
+ sub assembly)
OEM SIDE STRUCTURE WELDING ASSEMBLY
Side Structure Assembly
Tier 1 - supply
OEM main assembly OEM in-house stamping
Tier 1 - supply
OEM MAIN WELDING ASSEMBLY
Front Deck Assy

Roof Assy
Side Structure RH Assy
Main Body Assy Main Body Assy Front Floor Assy
Under Body Assy
Side Structure LH Assy

Rear Floor Assy
FITTING ASSEMBLY LINE FLOW
REAR DOOR ASSY TAIL GATE ASSY
Supply to Painting
Shop by Slat Conveyor
MAIN BODY ASSY
HOOD ASSY FENDER ASSY FRONT DOOR ASSY

TRANSFER EQUIPMENT
MAIN ASSY AT OEM
(SPOT WELD)
Front Deck Assy

Roof Assy
Side Structure RH Assy
Main Body Assy Main Body Assy Front Floor Assy
Under Body Assy
Side Structure LH Assy

Rear Floor Assy
BASIC EQUIPMENT WELDING ASSEMBLY
5) PAINTING
PROCESS
Stamping Body vendor Logistic
Painting of Body in White in accordance Trim & Final Fitting of trim & chassis components to
Paint
Minor
Engine &
Machining &
Injection vendor
Assembly of
Engines Sales
Casting & Machining vendor (detail next OK
page)
BASIC OF PAINTING PROCESS
• Painting Flow Process:- OVEN
ELECTRO DEPOSITION (ED)

PRE TREATMENT SEALING LINE MELTING SHEET
(15-25 MICRON) LINE
OVEN OVEN
ROCKER PRIMER & SECOND
COAT LINE BODY REPAIR, DRY PVC
MOIST SANDING SANDING, TAG UNDERCOATING
LINE (30-40 MICRON) RACK LINE LINE
OVEN
COLOR COAT / TOP INSPECTION,

MASKING LINE TAG RACK, PREPARATION COAT LINE (30-40 POLISH, TOUCH UP
FOR COLOR COATING LINE MICRON) & REPAIR LINE
❖ Generally, the different only at sealant line since every body has their own structure design.
❖ For MVF plant, Dry sanding line is located before the sealing line.
BASIC OF PAINTING PROCESS
PRE-TREATMENT
• Pre-Treatment
✓ A process that clean and prepare body in white (BIW) from oil and iron
metal chips before go to next ED process.
✓ There are 11 process involved:-
1) Hot water rinse (dip)
2) Pre-degreasing (spray)
3) Degreasing (dip)
4) Water rinse 1 (spray)
5) Water rinse 2 (dip)
6) Surface conditioning (dip)
7) Zinc Phosphate (dip)
11) De-ionised water rinse (spray)
ED COATING
• Electro-Deposition (ED)
✓ A process that employing the electrical reaction by using direct current.
✓ Current that flows from E.D membrane box carry +ve charge to the body that posses –ve
charge.
✓ ED mixture that contains +ve charge will attract to the –ve charge that possess by body.
✓ Summary : Membrane and ED mixture = +ve charge
Body = -ve charge
✓ There are 10 process involved:-
1) ED tank (dip)
2) UF water rinse 1 (spray)
8) Air blow (blow)
9) Oven (bake)
10) ED / Metal inspection (visual check)
✓ Thickness : 15-25 micron

✓ ED composition : 30% resin, 10% pigment & 60% H20
✓ 160°C-195°C, 20 minutes
ED COATING
PAINTING SEALANT & MELTING SHEET
• Sealing Line
– To close gap between metal joint.
– To prevent from water leakage.
– To prevent from corrosion and to
reduce vibration.
– 2 Types of sealant:-
• High Viscosity -> using sealing gun
• Low Viscosity -> using oiler
• Melting Sheet Line

– To absorb noise as well as to reduce noise and vibration.
– Material of melting sheet -> Tar + Paper
UNDERCOAT & REWORK
• PVC Undercoating
– A process to spray under lower and wheel housing area.
– To prevent corrosion and reduce vibration.
• Metal Repair Body, Dry Sanding, Preparation for primer coating

& Tag Rack
– To ensure the ED body are free from hump and dust.
SECOND COAT
• Primer Coating / Second Coat

– A process to spray second layer to the body after ED coat.
– To give adhesion layer between the top coat and ED layer in order to thicken
the layer.
– Thickness:-
• Vertical = 25-30 micron
• Horizontal = 30-35 micron
– Primers that has been implemented are:-
• Light Grey for bright color car.
• Dark Grey for dark color car.
• White for white based car.
• Rocker Primer
– A process in Second Coat.
– To prevent stone chipping at side sill.
REWORK & MASKING
• Moist Sanding
– To clean the surface that not good (NG) in quality.
– Defect that normally occurs due to dust.
• Masking Line
– To apply masking tape to the part for TF purpose.
• Tag Rack, Preparation for Color Coating / Top Coat

– To ensure the body are free from painting defect
• Dust
• Paint sagging
TOP COAT
• Color Coating / Top Coat
➢ To give the color coat in purposes of appearance, identification as well as attraction.
➢ Thickness:-
Types Solid Color Metallic Color
Base Coat 15-20 micron 25-30 micron
Clear Coat 25-35 micron 25-35 micron
➢ 2 Process involved:-
➢ Inner side spray by manpower.
➢ Outer side spray by robots.
➢ Why robot? Because:-

✓ Good workability
✓ Accurate and quality assurance
✓ High endurance
✓ Fast and consistence
✓ Not tired and obey to program
✓ Production speed increase
PLASTIC BUMPER PAINTING
6) PLASTIC AND
RUBBER PART
MANUFACTURING
Paint
Minor
Engine &
Machining &
Injection vendor
Assembly of
Engines Sales
page)
MOULDING
❑ Moulding
- The plastic is melted in the injection molding machine and
then injected into the mold, where it cools and solidifies into
the final part.
- most commonly used manufacturing process for the
fabrication of plastic parts.
- A wide variety of products are manufactured using injection
molding, which vary greatly in their size, complexity, and
application.
- The injection molding process requires the use of an :-
➢ Plastic Raw Material
➢ Molding Processing
➢ Mould
PLASTIC RAW MATERIAL
❑ ETYMOLOGY
- The word plastic is derived from the Greek (plastikos)
meaning capable of being shaped or moulded, from (plastos)
meaning moulded.
- It refers to their malleability, or plasticity during manufacture,
that allows them to be cast, pressed, or extruded into a variety of
shapes
- such as films, fibres, plates, tubes, bottles, boxes, and much more.
❑ What is Plastic?:
- Plastic are materials formed by long chains of carbon and hydrogen called
polymers, formed by units called monomers. The most important
characteristic of plastic is the capacity of deformation.
INJECTION MOULDING
INJECTION MOULDING & ASSEMBLY
MAIN COMPONENT- .
BLOW MOULDING
Aircond
air duct
EXTRUSION MOULDING
COMPRESSION MOULDING
TRANSFER MOULDING
MOULD
INTERIOR TRIM
INTERIOR TRIM
INTERIOR TRIM
HAZARD SWITCH
ALARM RESET SWITCH COMBINATION SWITCH
REAR DEFOGGER SWITCH COMBINATION METER
SWITCH BEZEL
IP CENTER SWITCH
1
3 IG SWITCH
4
2
5
8 7
6
POWER WINDOW
MIRROR SWITCH SWICH RH
POWER SOCKET
POWER WINDOW
SWITCH LH
INTERIOR TRIM
: P2-110 Only production, Current production car should be product in main line
※ Preliminary Assembly Flow (17 Process station)

O/Side Handle => Check Link => W/Strip => Wiring Harness => Garnish => Speaker
=> Glass Run => Regulator => Glass => O/Side Mirror => Inside Handle => Seal Trim
=> Door Trim => Door Function Test
< Front Door View> < Rear Door View>

INTERIOR TRIM
INTERIOR TRIM
A) Major processes in the Trim line

5) Front Bumper & Head Lamp
① No. Line Division Part Name Remarks
① - Beam, Front Bumper Body shop
② Trim Line Side Support Frt Bumper

④
③ Trim Line Head Lamp
④ Trim Line Fascia Ass’y Front Bumper
U/Body
- Chassis Line Fascia Ass’y Front Bumper Screw
M ounting
③
INTERIOR TRIM
A) Major processes in the Trim line

6) Rear Bumper & Rear Combi. Lamp
① No. Line Division Part Name Remarks
① Trim Line Stay, Rear Bumper
② ② Trim Line
Absorber, Energy
Rear Bumper
③ Trim Line Fascia Ass’y Rear Bumper
③ ④ Trim Line RR Combi. Lamp
U/Body
④ - Chassis Line Fascia Ass’y Rear Bumper Screw
M ounting
7) ENGINE
&
TRANSMISSION
AUTOMOTIVE ENGINE MANUFACTURING PROCESS
CASTING PLANT
PARTS MACH LINE
to TF Shop
ASSEMBLY LINE
to TF Shop
to TF Shop
PENGENALAN – Aliran proses cast iron
CORE MAKING
1.Crank Case
2.Water Jacket
3.Intake Oildrop MELTING
4.Exhaust Oildrop
Sand Sprue Core/strainer Flask In-Mold

MOLDING Pouring
Preparation Line setting Close Cooling
Flask Open
O
K
W/Jacket Shot Rough Gate
Painting Inspection Grinding Cooling
cleaning Blasting Fettling Cutting
C/BLOCK
N
G
Scrap
N
G
O
K
Blasting Product Mold Drag

Finishing Work
Process pick up & thumbling Push up
& Inspection
DELIVER gate pecking SMALL
Y PARTS
Normalizing
CR/S
4G1
HEAD SLAB CORE
OIL DROP CORE

( EXHAUST )
OIL DROP CORE

( INTAKE )
W/JACKET CORE
C/CASE CORE
CORE VS PRODUCT
MOULDING & SAND PREPARATION
manual proses - asas
KANDUNGAN
 Peraturan dan langkah-langkah keselamatan.

 Alat Perlindungan Diri. ( PPE )
 Hazard
 S.O.P
 Latihan
 Crane Handling
 Forklift Handling
 Emergency Case
 Larangan
 Melting Process
 Pengenalan Induction Furnace
 Sub-material
 Pemeriksaan CE ( Carbon Equivalent )
 LAB
 Kawalan Suhu Logam cair
 Pouring Process
 Activity weekend
 Check sheet/list
Pouring
process
▪ Forklift handling
▪ Innoculant weighing
▪ Inoculant charging
▪ Temperature check
▪ Slag remover
▪ Chill test
▪ Sample analysis
▪ Check sheet / record
▪ Ladle cleaning
▪ Ladle setting
▪ APM operation
▪ Making starting block
▪ Ladle heating
FINISHING 1:
• Cooling hanger menempatkan 150
hanger pada satu-satu masa
▪ Rough Fettling untuk pembuangan
burr,riser dan lebihan fin.
▪ Grinder mesin memotong 4 permukaan
cyl.block.
▪ Untuk pembersihan pasir melekat,
mesin Shotblasting digunakan iaitu
DISA DV2 menggunakan shot ball.
▪ WJSB mesin yang mengunakan robot
ABB,Drilling dan Shotblasting untuk
pembersihan water jacket.
▪ Painting,robot dan oven digunakan
untuk kerja-kerja mengecat
Sand Casting Process Flow
Aluminium
Ingot CASTING PLANT
Mould to produce
Sand Core
Deliver to
Machining
Sand Core
Assemble in
Sand Box
Sand Core
CASTING ALUMINIUM CYLINDER HEAD
PROCESS FLOW
PROCESS OUTLINE
Melting Casting Cooling Gate Knocking T4 Sand

Process LPDC Process Remova process Baking
Manual tranfer
Finishing Line Process
Core Storage
(Buffer)
Vibrating
Core Making
Process
Manual
core
setting
Palletizing Final Leak Washing Face

Inspection Test Machine Milling
Cubing Line Process
ETM
Dies Casting Process Flow
Machining and Assembly Line Layout
B.CAP
C. BLOCK MACH
CRANK/S MACH
C. HEAD MACH
CAM/S MACH
EXH. MACH
ENGINE ASSY 1
ENGINE ASSY 2
2
120 m x 230 m = 27,600 m
Machining Line
From Casting
Plant
Send to Engine
Assembly Line
Engine Assembly flow
START
CR/S
WASHING
RECEIVE C/B SCAN BAR
FROM PPC CODE/CE.C CYLINDER BLOCK ASSY
ASSEMBLE
TARGET
CYL OK PIN DOWEL &
ENGINE NO C/B TURN C/BLOCK WHEEL,
BORE F/R BUSHING
PUNCHING OVER WASHING BEARING &
CHECK INSTALLATION
OIL PAN PIN
DOWEL
NG
REPLACE C/ROD SUB ASSY
WASHING PISTON
LOADING ENG
W/PUMP, FR OK TORQUE IN CRANKING C/ROD KNOCK IN
DISMANTLE
CASE & OIL PAN N/R B/CAP
ON PALLET SPEC TORQUE PISTON
INSTALLATION BOLT
REPAIR
NG
RECEIVED CYLINDER HEAD ASSY FINISHING ASSY
C/H
INSTALL INSTALL ASSY FLYWHEEL
INSTALL ADJUST
INTAKE VALVE
A/C NUT
T/BELT
MANIFOLD COMPRESSOR RUNNER
C/H
INSTALLATION C/H N/R SHORT
BLOCK OK
LEAK
TESTE LEAK
R
NG TESTER
REPAIR (OIL
REPAIR
NG LINE/WATE
INSPECTION AND TESTING R LINE)
INSTALL
SUPPLY TO FINAL HOT TEST CLUCTH OK
END PPC
LOADING
INSPECTION BENCH PLATE &
COVER
8) TRIM PART ASSEMBLY
&
FINAL PROCESS
Paint
Minor
Engine &
Machining &
Injection vendor
Assembly of
Engines Sales
page)
Vehicle Assembly Layout
Vehicle Assembly Process
2-Chassis
1-Trim
1-Final
1-Testing
PROSES-PROSES PENTING DALAM ASSEMBLY

1) TRIM
A) PEMASANGAN HARNESS
B) PEMASANGAN CARPET
C) PEMASANGAN HEADLINING
D) PEMASANGAN HEADLAMP DAN REAR COMBI
E) PEMASANGAN ABSORBER
F) PEMASANGAN INSTRUMENT PANEL

2
WIRE-DEFOGGER
1
W/H - BODY
3
W/H – FUEL TANK
1
1
W/H – INST PANEL
4
7 PCB BOX
5
W/H - FRONT
6
W/H – BATTERY
1
8 0
W/H – TAIL GATE
W/H – FRT DOOR
W/H – REAR DOOR

2-Chassis
1-Trim
1-Final
1-Testing

2) CHASSIS
A) PEMASANGAN PIPE COMPLETE
B) PEMASANGAN FUEL TANK
C) PEMASANGAN REAR SUSPENSION
D) PEMASANGAN FRONT SUSPENSION
E) PEMASANGAN ENGINE
F) PEMASANGAN EXHAUST
G) PEMASANGAN TYRE
CHASSIS
A chassis consists of an internal framework that supports a man-made

object in its construction and use. It is analogous to an animal's skeleton.
An example of a chassis is the under part of a motor vehicle, consisting of
the frame (on which the body is mounted). If the running gear such as
wheels and transmission, and sometimes even the driver's seat, are
included then the assembly is described as a rolling chassis.
CHASSIS
CHASSIS
G) Chassis Process Layout

②
③
⑥
⑧
⑤
④
No Part Name Remarks No Part Name Remarks
① Pipe, Fuel & Brake ⑤ Engine & T/M Ass’y With Radiator module
② RR Damper ⑥ Front Exhaust Pipe
③ Fuel Tank ⑦ Rear Muffler
④ RR suspension ⑧ Drive shaft Castle Nut T/Q : 230 Nm (200 ~ 260 Nm)
Wheel & Tire Mounting T/Q : 100Nm (90 ~110 Nm)
CHASSIS
Suspension system
CHASSIS
Heat & fluid system
CHASSIS
Brake system Chassis design
ENGINE DOCKING
< Engine Sub Ass’y> < Sub Frame Loading > < Engine Ass’y Lading to Sub Frame >
<Bracket Ass’y front/rear roll

< Radiator Module Loading> <Drive Shaft & Corner Module>
mounting Connection>
ENGINE DOCKING
F) Engine & T/M Mounting (With radiator module) : 3 Process station
<Engine & T/M mounting : Chassis Line > <Bracket Ass’y TM mounting to body : Trim Line >
Brkt ASSY, right mounting / Brkt

ASSY,
TM mounting Tightening & T/Q On
the
platform
=> Platform height : FL+1,500mm
ENGINE DOCKING
Heat & fluid system

2-Chassis
1-Trim
1-Final
1-Testing

3) FINAL ASSEMBLY
A) PEMASANGAN CERMIN HADAPAN DAN

BELAKANG
B) PEMASANGAN SEAT DEPAN DAN BELAKANG
C) PEMASANGAN STEERING
D) PEMASANGAN PINTU
E) PENGISIAN MINYAK ENGINE, COOLANT,

MINYAK PETROL
FINAL ASSEMBLY
Steering system
FINAL ASSEMBLY
H) Wheel & Tire mounting
- 1 spindle N/runner will be install : 1 process
- 4 spindle N/runner will be install : 2 process (including the tire set-up)
PCD size : 114.3
I) Engine Room Package
Brake Reservoir Brkt Ass’y TM

mounting
A/C pipe
Washer Reservoir
Fuse Box
Power Reservoir Battery
LLC Reservoir
Radiator Hose
2-Chassis
1-Trim
1-Final
1-Testing

4) TESTING
A) ALIGNMENT
B) MENYELARAS KETINGGIAN LAMPU
C) UJIAN KELAJUAN
D) UJIAN SPEDOMETER
E) UJIAN BRAKE
F) UJIAN ABS
Shower Test
Shower Test
• Arthur Ashe, The Legendary Wimbledon
Player was dying of AIDS
• Which he got due to Infected Blood he recived
during a Heart Surgery in 1983
• He received letters from his fans, one of which
conveyed:
• “why did God have to select you for such a
bad disease??”
• To this Arthur Ashe replied:
• 50 Million children started playing Tennis,
• 5 Million learnt to play Tennis,
• 500 000 learnt Professional Tennis,
• 50 Thousand came to Circuit,
• 5 Thousand reached Grandslam,
• 50 reached Wimbledon,
• 4 reached the Semifinals,
• 2 reached th Finals and
• When I was holding the cup in my hand,
• I never asked God :Why Me?”
• Happiness keeps you Sweet!!
• Sorrows keeps you Human!!
• Failure keeps you Humble!!
• Success Keeps you Glowing!!
• But only, Faith keeps you Going.
• Sometimes you are unsatisfied with your life,
• While many people in this world are dreaming
of living your life..
• A child on a farm sees a plane fly overhead &
dreams of flying.
• But, A pilot on the plane sees the farmhouse
& dreams if retuning home.
• That’s life!! Enjoy yours..
• If wealth is the secret to happiness,
• Then the rich should be dancing on the
streets.
• But only poor kids do that
• If power ensures security, then VIPs should
walk unguarded.
• But those who live simply, sleep soundly.
• If beauty and fame bring ideal relationships,
• Then celebrities should have the best
marriages.
• Live simply.(hidup lah dgn sederhana)

• Walk humbly.(sentiasa merendah diri)
• And love genuinely..!(dan cinta sejati..!)
PROCESS STUDY
ASSEMBLY PROCESS
NEW PROJECT
Line Performance Setup Profile (Base on 5.2u/Hr.)
W O R K P R O CE SS DISTR IB UTIO N L INE SP E E D v s W O R KSTA TIO N
B a se model : CM6L R P ML MW 3 ( G CC) U/Hrs 1 4 5 6 7
Operation Area On Line Off Line Total C/time 3600 900 720 600 514
Branch Trim Chassis Final S/assy Acc W/stn 6.2 24.7 30.9 37.1 43.3
Work station 7.1 6.1 13.7 0.7 27.6 + (Cpy)
GXM 5132.7 4403.9 9835.9 487.6 19860.1 Total 6.2 24.7 30.9 37.1 43.3
Total Volume depand on

L INE SE TUP DA TA L INE SE TUP E L E ME NT
TOTAL SEC/HOUR 3600 Sec Cycle time 720 sec Workbay Facilities Tools Prod. Doc. Design
Plan Volume (HRS) 5 unit On Line Work Station Plan Actual 27.6 OK OK On going
Sec 60 Sec Trim 7.1 8
Min 12 Min Chassis 6.1 7
Plan Volume (DAY) 40 unit Final 13.7 14
Working Hours 28800 sec Sub.Assy 0.7 1 P R O P O SE MA NP O W E R
Working Hours 8 hrs
PITCH TIME 720 sec Total On Line Workstation 26.9 stn Plan manpower Actual Diff
Line Pitch 5.5 mtr Sub.Assy.Station 0.7 stn A/F 1 A/F A/F
Std PROCESS TIME (M) 22266.46 sec Total w/stn 27.6 stn L/K 1 L/K L/K
6.2 hrs Repair manhour hrs worker worker worker
Repair Repair Repair
W O R K P R O CE SS DISTR IB UTIO N G R A P H Dvr / Tsr Dvr / Tsr Dvr / Tsr
WORK PROCESS DISTRIBUTION GRAPH Total Total Total
10000
SEC. 5000 Base model

SEC.
GROUP Trim Chassis Final S/assy
0
Trim Ch assis Fin al S/assy SEC. 7539.1 4403.9 9835.9 487.6 22266.46
BRANCH
Pr odu c t ion Volu me /Year

U/H U / Day U / M ont h U / Y e ar Prepared Checked Approved
5 40 800 9600
Total w/Day 20 12
PROCESS TIME
STANDARD WORKING TIME TABLE (WORK CODE LIST)
GT Mengambil dan membawa part PO Set part 3 TB Set bolt FT Mengetatkan manual bolt&nut
1 2 TB 4
GT -- PO - X X -- FT X X --
bil.langkah 1 2 3 4 situasi 2 sebelah tangan kedua belah tangan Kuantiti 1 2 3 4 5
Kuantiti 1 2 3 4 5
kod berat part kod 01 02 03 04 kod SH BH
Bentuk part kod 01 02 03 04 05 Bentuk part kod 01 02 03 04 05
~6kg 06 5.2 5.8 6.4 7.0 bil. 1 2 3 4 5 1 2 3 4 5
~12kg 12 6.0 6.6 7.2 7.8 Bolt/nut sahaja N1 2.6 4.7 6.8 8.9 11.0
BN situasi 1 kod 01 02 03 04 05 01 02 03 04 05 Tanpa washer plate LW 1.6 3.2 4.8 6.4 8.0
~18kg 18 6.8 7.4 8.0 8.7 Nut+spring washer N2 3.0 6.0 9.0 12.0 15.0
Tolak tak diperlukan P1 1.9 3.8 5.7 7.6 9.5 2.3 4.6 6.9 9.2 11.5 Dengan washer plate WW 2.6 5.2 7.8 10.4 13.0
melebihi 18kg 19 8.7 9.3 9.9 10.5 Nut+s/w+p/w N3 3.8 7.6 11.4 15.2 19.0
~6kg 06 3.0 3.6 4.2 4.8 Tolak sedikit P2 2.7 5.4 8.1 10.8 13.5 3.4 6.8 10.2 13.6 17.0
Tolak kuat P3 4.6 9.2 13.8 18.4 23.0 5.0 10.0 15.0 20.0 25.0 bolt washer plate spring washer
~12kg 12 3.4 4.0 4.6 5.3 washer plate
ST Note 1. Masa utk membawa part ke installation point
~18kg 18 3.9 4.5 5.1 5.7
melebihi 18kg 19 4.8 5.4 6.0 6.6 2. Tolak sedikit : jika susah utk di install
BN : tunduk utk mengambil part 3. Tolak kuat :jika sangat susah utk di install bolt or nut
ST : part yg di ambil sambil berdiri 4. Kod ini juga digunakan utk part lain, jig dan tool.
Masa mengambil part (termasuk 0.3m berjalan)

kod ini sudah tidak digunakan lagi (berjalan 1. Part kecil : 1s / 1 part
dan membawa di kira sebagai 'auxiliary 2. Part besar dan panjang : 2s / 1 part
3. Standard part : 1s / 1 jenis
NL Mengetatkan bolt&nut
menggunakan nut runner QL QL wrench
TT Mengetatkan set bolt&nut BL Mengetatkan bolt NU Mengetatkan nut 9
5 6 7 8
8
TT X X-- BL X X --- NU X X --- NL X X -- QL X X --
kuantiti 1 2 3 4 5 kuantiti 1 2 3 4 5 kuantiti 1 2 3 4 5 kuantiti 1 2 3 4 5 bahagian 1 2 3 4 5
Panjang bolt kod 01 02 03 04 05 situasi kod 01 02 03 04 05 Tool size diagonal kod 01 02 03 04 05
situasi kod 01 02 03 04 05 ~10mm 10 3.9 6.8 9.7 12.6 15.5 bentuk kod 01 02 03 04 05
Pengetatan ST 6.9 13 19 24.6 30.5 kurang drpd 12mm ST 3.7 5.6 7.5 9.4 11.3
Pengetatan ST 2.7 4.5 6.3 8.1 9.9 ~16mm 16 4.0 7.0 10.0 13.0 16.0 standard ST 3.9 6.8 9.7 12.6 15.5 kurang drpd 14mm MT 5.5 8.8 12.1 15.4 18.7
~22mm 22 4.1 7.2 10.3 13.4 16.5
24mm~ 24 4.2 7.4 10.6 13.8 17.0 Bolt or Nut melebihi 17mm LT 7.2 12.2 17.2 22.2 27.2
Bo lt Nut
run n er
diagonal
Bolt or Nut Nut QL Wrench
Bolt length Socket wrench
Impact wrench from neck
Impact wrench impact wrench
(Base time)low noise impact (alpha type) + 0.40s / axle

(UX type) + 0.50s / axle
FN Ketatkan flare nut sementara TW Torque wrench mudah CN Menyambungkan wire harness HN Clamp harness
13
10 11 12 -- HN - --
FN X X --- TW X X --- CN -
kuantiti 1 2 3 4 5
kuantiti 1 2 3 4 5 bahagian 1 2 3 4 5 kuantiti 1 2 3 4 5
kod bentuk kod 01 02 03 04 05
Part size diagonal kod 01 02 03 04 05 Tool size diagonal kod 01 02 03 04 05 kod Bentuk kod 01 02 03 04 05
clamping W/H
kurang drpd 10mm 10 4.5 9.0 13.5 18.0 22.5 kurang drpd 10mm ST 4.1 6.7 9.3 11.9 14.5 01 NL 2.0 4.0 6.0 8.0 10.0
kurang drpd 14mm 14 5.9 11.8 17.7 23.6 29.5 kurang drpd 14mm MT 5.3 9.1 12.9 16.7 20.5 01 1.5 3.0 4.5 6.0 7.5
04 Tanpa lock NL 2.3 4.6 6.9 9.2 11.5
melebihi 17mm 17 7.2 14.4 21.6 28.8 36.0 melebihi 17mm LT 6.3 11.1 15.9 20.7 25.5
Dgn lock LO 2.7 5.4 8.1 10.8 13.5
diagonal
f lare nut diagonal

06 Tanpa lock NL 2.8 5.6 8.4 11.2 14.0
clamping after
Dgn lock LO 3.3 6.6 9.9 13.2 16.5 W/H setting 02 1.2 2.4 3.6 4.8 6.0
Torque Wrench
10 Dgn lock LO 4.0 8.0 12.0 16.0 20.0
CL
pin connector less than 5P-9P
bend clip
lock
HO Masukkan hose HB Install hose band&clip 01 06
after W/H
04 1.0 2.0 3.0 4.0 5.0
14 15 setting
HO X X-- HB X X ---
bahagian 1 2 3 4 5 kuantiti 1 2 3 4 5
bentuk part dan situasi kod 01 02 03 04 05 part kod 01 02 03 04 05 bend clip
less than 4P on both
Part dimasukkan f ixed in 10mm clip 01 2.3 4.6 6.9 9.2 11.5
WF 2.9 5.8 8.7 11.6 14.5 lock hand after 05 1.3 2.6 3.9 5.2 6.5
Insert allowance 30mm band 02 1.7 3.4 5.1 6.8 8.5 more than W/H setting
04 10
Part dimasukkan moving in 10mm Clip Band 10P
(pegang sebelah tangan) WM 3.1 6.2 9.3 12.4 15.5 Setting sebelah tangan 01 1.4 2.8 4.2 5.6 7.0
Insert allowance 30mm 01 02
Setting kedua belah tangan 02 1.9 3.8 5.7 7.6 9.5
Part dimasukkan f ixed in 3mm
VF 1.5 3.0 4.5 6.0 7.5
Insert allowance 30mm AC
assemble clamp
Insert f lexible hose JB 2.0 4.0 6.0 8.0 10.0 on W/H for ASSY
installation
fixed or free hose
w/h = wire harness

inserted part
inner diameter
insert allowance
CL Install clip clamp GR Install grommet TA Meletakkan adhesive tape 20 CS Meletakkan protector
16 17 19
CL - -- GR X X -- TA - -- CS X X --
Part dimasukkan f ixed in 10mm clip 01 2.3 4.6 6.9 9.2 11.5 less than 4P
WF 2.9 5.8 8.7 11.6 14.5 lock hand after 05 1.3 2.6 3.9 5.2 6.5
Insert allowance 30mm band 02 1.7 3.4 5.1 6.8 8.5 more than W/H setting
04 10
Part dimasukkan moving in 10mm Clip Band 10P
(pegang sebelah tangan)
Insert allowance 30mm
Part dimasukkan f ixed in 3mm
Insert allowance 30mm
WM 3.1 6.2 9.3 12.4 15.5
VF 1.5 3.0 4.5 6.0 7.5

01 02
AC
Setting sebelah tangan
Setting kedua belah tangan
01
02
1.4
1.9
2.8 4.2 5.6 7.0
3.8 5.7 7.6 9.5
assemble clamp
Insert f lexible hose JB 2.0 4.0 6.0 8.0 10.0 on W/H for ASSY
installation
fixed or free hose
PROCESS TIME inserted part

inner diameter
w/h = wire harness
insert allowance
CL Install clip clamp GR Install grommet TA Meletakkan adhesive tape 20 CS Meletakkan protector
16 17 19
CL - -- GR X X -- TA - -- CS X X --
kuantiti 1 2 3 4 5 kuantiti 1 2 3 4 5 panjang bil. 1 2 3 4 5 bil.keping 1 2 3 4 5
kod bentuk kod 01 02 03 04 05 bentuk kod 01 02 03 04 05 situasi kod mm kod 01 02 03 04 05 bentuk part kod 01 02 03 04 05
more than 10 10 2.9 5.8 8.7 11.6 14.5
2 times pushing
15 15 3.2 6.4 9.6 12.8 16.0 utk w/h kurang L=200mm 19 3.0 6.0 9.0 12.0 15.0
required
01 2.0 3.6 5.2 6.8 8.4 GR 3.9 7.8 11.7 15.6 19.5 Penampalan 20 20 3.3 6.6 9.9 13.2 16.5 utk w/h lebih L=200mm 20 4.2 8.4 12.6 16.8 21.0
biasa 25 25 3.5 7.0 10.5 14.0 17.5
HN (termasuk ST 30 30 3.6 7.2 10.8 14.4 18.0
only 1 pemotongan) 35 35 3.8 7.6 11.4 15.2 19.0
02 1.9 3.4 4.9 6.4 7.9 pushing
PR 40 40 4.4 8.8 13.2 17.6 22.0
1.5 3.0 4.5 6.0 7.5 L protector
45 45 4.7 9.4 14.1 18.8 23.5
50 50 4.9 9.8 14.7 19.6 25.5
without hook
10 10 0.7
01 2.0 3.0 4.0 5.0 6.0 15 15 0.9
BU Meletakkan pubattalion tape 20 20 1.0
18
BU X X --- 25 25 1.2
with hook
Penampalan 30 30 1.3 LA Meletakkan label
bahagian 1 2 3 4 5 21
02 2.2 3.4 4.6 5.8 7.0 bersambung NX 35 35 1.4 LA X X --
part size kod 01 02 03 04 05 ke corner 40 40 1.5 bil.keping 1 2 3 4
10mm 10 0.8 1.6 2.4 3.2 4.0 45 45 1.6
CL
50 50 1.7 bentuk part kod 01 02 03 04
15mm 15 0.9 1.8 2.7 3.6 4.5
surrounded
55 55 1.8
03 2.7 4.1 5.5 6.9 8.3 20mm 20 0.9 1.8 2.7 3.6 4.5 kurang dr 50mm x 80mm 02 5.0 10.0 15.0 20.0
60 60 1.9
hook
with
25mm 25 1.0 2.0 3.0 4.0 5.0 Tambah masa berdasarkan 80

30mm 30 1.1 2.2 3.3 4.4 5.5 masa utk menolak di bend CN 0.7 1.4 2.1 2.8 3.5
with 2
step 35mm 35 1.1 2.2 3.3 4.4 5.5 line bagi penampalan
04 4.5 7.7 10.9 14.1 17.3 50
clips 10 10 0.2 0.4 0.8 1.0 1.2
40mm 40 1.2 2.4 3.6 4.8 6.0
15 15 0.3 0.6 0.9 1.2 1.5
45mm 45 1.2 2.4 3.6 4.8 6.0 20 20 0.4 0.8 1.2 1.6 2.0
with case type nut
50mm 50 1.3 2.6 3.9 5.2 6.5 25 25 0.4 0.8 1.2 1.6 2.0 label
NS 01 2.2 4.0 5.8 7.6 9.4 55mm 55 1.4 2.8 4.2 5.6 7.0 Potong 30 30 0.5 1.0 1.5 2.0 2.5
sahaja CT 35 35 0.5 1.0 1.5 2.0 2.5
60mm 60 1.4 2.8 4.2 5.6 7.0
40 40 0.6 1.2 1.8 2.4 3.0
45 45 0.6 1.2 1.8 2.4 3.0
PC Install pin cotter
50 50 0.7 1.4 2.1 2.8 3.5 22
55 55 0.7 1.4 2.1 2.8 3.5 PC X X --
HH Ketuk dgn tukul WT Faktor berat 60 60 0.8 1.6 2.4 3.2 4.0 kuantiti 1 2 3 4
25
23 10 10 1.9 3.8 5.7 7.6 9.5 kod 01 02 03 04
HH X X --- WT X X -- X X
15 15 2.0 4.0 6.0 8.0 10.0 01 4.5 9.0 13.5 18.0
bil. 1 2 3 4 5 Berat part kod f aktor 20 20 2.0 4.0 6.0 8.0 10.0
pin cotter
situasi kod 01 02 03 04 05 ~6kg 06 1.00 Tampal 25 25 2.1 4.2 6.3 8.4 10.5
PT
tanpa positioning 01 2.4 3.4 4.4 5.4 6.4 7 - 12kg 12 1.17 sahaja 30 30 2.2 4.4 6.6 8.8 11.0
35 35 2.3 4.6 6.9 9.2 13.5
sekali positioning 02 2.7 3.7 4.7 5.7 6.7 13 - 18kg 18 1.35
40 40 2.8 5.6 8.4 11.2 14.0 bending
positioning setiap kali 03 2.7 4.5 6.3 8.1 9.9 over 19kg 19 1.75 45 45 3.0 6.0 9.0 12.0 15.0
FH Tolak dan tekan dgn tangan

24
FH -- 26 NA Faktor Kesukaran
Pengambilan Masa
situasi 2 Perlahan Kuat Secara Terus
kesukaran kod f aktor
kod LT HV
normal D1 1.00 QX OOOO - OO 12.8 Instruction paper(base
bil. 1 2 3 4 5 1 2 3 4 5
situasi 1 kod 01 02 03 04 05 01 02 03 04 05 sec
sedikit sukar D2 1.15 4 sec x No. of paper x 1.15
Tolak dgn jari FP 1.0 2.0 3.0 4.0 5.0 1.2 2.4 3.6 4.8 6.0 0 1 2 8 0 1
indirect manpower
Tolak dgn tangan HH 0.8 1.6 2.4 3.2 4.0 1.0 2.0 3.0 4.0 5.0
sangat sukar D3 1.22 time (sec) times
Trim & Final Shop Sample Lay-out
Application of KANBAN in TF Shop
Application of LEAN in TF Shop
PONSIKOU
TERIMA KASIH
THANK YOU
ARIGATO
DANKE SCHON
262

Basic Manufacturing Process

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Basic Manufacturing Process

Uploaded by

Copyright:

Available Formats

MODULE 1:

OVERVIEW OVERALL VEHICLE

Source: MAA & Gaikindo

MANUFACTURING EMPLOYMENT EMPLOYER

DOMESTIC 487,176 548,115 536,905 605,156 600,123 627, 753

IMPORT 25,515 44,897 35,769 68,415 89,897 86,588

Unloading CBU car

Boxes of part and component Large Stamping

STAMPING PAINTING TRIM &

TOOLING ENGINE &

Metal Body Component vendor Logistic

Casting & Machining Component vendor

Example of OEM Manufacturing Layout

Style theme AT Ext. style Maj. Freeze DQCM

Base data check

R&D Design PART DRAWING

MULE CAR ODB Aero dyna. Pre L/O Production L/O

& Mule car test Pilot test

Validation Design master vehicle (interior) PV test

Basic plan / Line concept

Style theme AT Ext. style Maj. Freeze DQCM

SCALE MODELLING Class "A" surfacing

Base data check

R&D Design Mule design

Verification Mule car build-up Off-tool prototype build-up

& Mule car test Pilot test

Validation Design master vehicle (interior) PV test

Basic plan / Line concept

A few sample of Proton

Style theme AT Ext. style Maj. Freeze DQCM

& Mule car test Pilot test

Validation Design master vehicle (interior) PV test

Basic plan / Line concept

Style theme AT Ext. style Maj. Freeze DQCM

Rendering FULL MODELLING SOP

Base data check

R&D Design Mule design

& Mule car test Pilot test

Validation Design master vehicle (interior) PV test

Basic plan / Line concept

Style theme AT Ext. style Maj. Freeze 18 DQCM

Base data check

R&D Design Mule design

MULE CAR ODB Aero dyna. Pre L/O Production L/O

& Mule car test Pilot test

Validation Design master vehicle (interior) PV test

Basic plan / Line concept

Style theme AT Ext. style Maj. Freeze DQCM

SCALE MODELLING Verification model

Base data check

R&D Design PART DRAWING

MULE CAR ODB Aero dyna. Pre L/O Production L/O

& Mule car test Pilot test

Validation Design master vehicle (interior) PV test

Basic plan / Line concept

Style theme AT Ext. style Maj. Freeze DQCM

SCALE MODELLING Verification model

Base data check

R&D Design PART DRAWING

MULE CAR ODB Aero dyna. Pre L/O Production L/O

& Mule car test Pilot test

Validation Design master vehicle (interior) PV test

Basic plan / Line concept

DMU can be used :-