CLO3: Discuss the

manufacturing process
of automotive vehicles.
 What is manufacturing
process of automobile?

• Car manufacturing starts with sheets of metal as

building cars often involve recycled materials. It’s
worth noting that artisans build classic cars by hand
but most of today’s cars are made by robots on an
assembly line.
Obtaining And Reworking Raw Materials

• Car manufacturers need raw materials to

transform the car from concept into
reality. With climate change a big talking
point, many companies are looking for
more sustainable, lightweight and cost-
effective materials to keep up with the
demand for ‘greener’ products.
 Design, Engineering
And Car Manufacturing

• Carmakers have a tough job as the design must meet the

public’s needs and desires where the process often
involves many revisions to find the perfect fit. The interior
and exterior must also be attractive and functional to
potential buyers while including innovative technologies
that make the car newsworthy and competitive.
• Smaller-scale models of the car are made in 2D and
3D to help engineers test the car’s design. This
includes aerodynamics, safety, hot and cold weather,
fuel economy, electrical functionality and cost
analysis among others. The car manufacturing
process can only begin once the design and
engineering specifications have been checked, tested
and approved.
• Even though each car manufacturer follows its own
process, there are some set standards when it comes
to making a car. Read all about the car manufacturing
process in this simple step-by-step guide.
 Stamping Or Press Shop

• Production starts at the stamping plant or press shop.

Here, it supplies the necessary steel parts with stamping
dies to form specific parts. Robots in the assembly line
create and stamp sheet metal parts for the bodywork,
including doors, roof and side frames which they later add
to the mainframe of the car.
Welding Or Body Shop
• The next stop on the assembly line is the
body shop where individual pressed steel
parts are put in place and on the desired
single-body structure. This second step in
the car manufacturing process also
involves joining the sheet metal and
aluminium parts to create the final form.
 Paint Shop As
Part Of The Assembly Line
• At the third step in the car manufacturing process, the
body shop sends the entire frame to the paint shop where
they add a coating to protect against corrosion. This is
done in a dust-free environment to ensure only the best
results. After applying a coat of paint, the car body
undergoes a paint inspection system to rule out any
irregularities.
Engine Fitment and Assembly
• The engine assembly line is the heart of the car
manufacturing process as this is where all the
testing takes place. It involves multiple aspects,
such as the performance of each engine cylinder.
It’s on this assembly line where they attach
various parts to the painted body shell, including
the engine, chassis, and tires. The last part of the
assembly process involves mounting certain
mechanical elements from the driving position
and mirrors to the interior trim of the vehicle.
 Final Inspection and Testing

• When all of the stages of production have been

completed, the fully-assembled car is then thoroughly
inspected to ensure there are no defects before sending it
to car dealerships. This process also involves checking for
any imperfections or inconsistencies with the exterior or
interior.
Some of the checks include the following:

• the engine is started and stopped several times

• steering alignment is adjusted
• headlights are checked for brightness and reach
• brakes are tested for safety
• heavy water pressure tests to find leaks
• the car’s programming
• electrical units will be checked to ensure safety
and accessibility
 Final Inspection and Testing

• Finally, they perform crash tests to observe how the car

handles certain impact and to see how the airbags and
seat-belts fare. If the car passes all tests and requires no
further changes, the company can now present it to the
market, develop a marketing strategy and define the best
price.
Six types of
manufacturing processes

Depending on your type of business or

product, one manufacturing process
might work better than another for your
company. Here are six types of
manufacturing processes used in
industries worldwide today:
 Job shop manufacturing
• Job shop manufacturing
• Repetitive manufacturing
• Discrete manufacturing
• Batch process manufacturing
• Continuous process manufacturing
• 3D printing
 Other types of manufacturing processes
Machining
Machining uses power-driven tools to shape solid materials and metals by removing extra
materials from the piece, usually by trimming. Machining is the foundation of the industry and
includes things such as presses, chip-making tools and modern machinery.
Joining
Joint patterns consider load factors, assembly performance, upkeep and operations. Bolting is a
standard fastening method while welding is more cost-effective and reduces excess weight,
because it doesn't require overlapping materials, fasteners or mounted parts in between.
Forming
Metal forming bends, spins or stretches using a metal press, die or punching tools. Forming is
expensive, though you can reuse equipment by changing the dies.
Casting
Casting involves a solid dissolving into a liquid when heated and poured into a mold or cavity.
Casting can create complex or simple shapes from any kind of meltable metal with a wide option
for designs.