Automobile Manufacturing Plant

ASSEMBLY PROCESS
 The Parts
 Start With the Frame
 Installing the Parts
 Engine and Transmission Installed
 Building the Shell
 Final Body Components
 Inspection and Washing
 Paint
 The Inner Workings
 The Shell and the Frame
 Test the Car
COMPONENTS
Auto parts are supplied from owned plants or
from independent plants
PROCESS FLOW
PROCESS FLOW continue…
STAMPING
CHASSIS
CHASSIS
BODY
• Body is built on a separate assembly line from
chassis
• The floor pan is the largest body component
to which a multitude of panels and braces will
subsequently be either welded or bolted. As it
moves down the assembly line, held in place
by clamping fixtures, the shell of the vehicle is
built.
UNDERBODY
SIDE BODY
WELDING
BODY IN WHITE
PAINT

Undercoat drying

E-coat Baking
E-COAT
UNDERCOAT
WATERBORNE PAINT, OUTMODED
DRYING OVEN
PAINT, POWDER COAT
PAINT CONTROL ROOM
INTERIOR ASSEMBLY
TRIM LINE
TRIM LINE
WINDSHIELDS INSTALLED BY ROBOTS
BODY AND CHASSIS MATE
FINAL ASSEMBLY, TRIM: TIRES, BATTERIES,
GASOLINE, ANTI-FREEZE
FINAL INSPECTION
CONTROL STRATEGY
Control objective(s)

Input variables

Output variables

Constraints

Operating characteristics

Safety, environment, and economical considerations

Control structure
CONTROL OBJECTIVE(s)

●
● Optimized welding process
BODY SHOP ●
● Maintain supply of metal input
●
● Maintain proper size, shape and position of parts to be weld

●
● To maintain the proper temperature of the process
PAINT SHOP ●
● Maintain the amount and pressure of paint flow
●
● Consistency in the speed

●
● Proper speed conveyor
ASSEMBLY AREA ●
● Weight-rate flow of body and engine
●
● Counting and control of unit production
INPUT AND OUTPUT VARIABLES

Specificatio
n
Body Parts

Paint
CONSTRAINTS
●
● Welding time
BODY SHOP ●
● The specified temperature
●
● Amount of material used

●
● Specified temperature for drying process
PAINT SHOP ●
● Maintain the amount and pressure of paint flow
●
● Consistency in the speed

●
● Speed of conveyor
ASSEMBLY AREA ●
● Balancing the load
●
● Schedule performance
OPERATING CHARACTERISTICS
CONTROL STRUCTURE
CONVEYOR SPEED CONTROL
H
Idlers
G

WB

Motor
WS
SS

M C SCR
 ROBOT CONTROL IN ASSEMBLY LINE

Motion
Planner
sensors sensors

Trajectory
controller Robot Environment
planner
AUTOMATED ASSEMBLY PROCESS
REFERENCEs
• Discovery Channel Show: BMW Super Factory
THANK YOU