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PARVINDER SANDHU
B.TECH,ADE-VI
R140208015
V Industrial exposure and knowledge.

V To correlate our theory knowledge with real world

practicality.

V Knowledge of parameters and limitations during

manufacturing of a vehicle.

V Understanding of the expectations from an engineer in

industry.
V Visited Xylo body shop.
V Application of robotics in the real time.
V Body assembling was completely robotic based.
V Robots perform their job in highly accurate and efficient
manner.
V Capable of handling load.
V Robots assemble and spot weld different panels.
V Large profit in terms of time and cost.
V Assembly of chassis and body shell.
V Trims included carpet, seats, door attachments,
windscreens, wipers, side mirrors etc.
V After trimming ,vehicles are tested for 3D motion in
case of speed breakers and other road irregularities
V Then the steering geometry is approximated and
adjusted(I,e. Camber, Castor etc).
V After this the final testing is done.
V (e also saw master bodies of XYLO and SCORPIO.

V The exact process of vehicle fabrication is shown in the

forthcoming slides.
V Then the body with chassis( after painting) is sent to the
trim line where various trims are added like seats,
window panes, front and rear mirrors, windscreen wipers,
side mirrors, door trims, boot trims, dashboard, door
handles etc.

V Then seals are applied and water drenching test is done

with fluorescent water jet to check leakage.
V Research, testing and approval of vehicles of various
companies.
V Testing of tyres, fuel, lubricants, engines .
V Testing machines are numbered based on AIS standards.
V tests are conducted as:
V Endurance test.
V Reference high speed test.
V Plunger test.
V Bead unseating test.
V Rear wall Strength Test set up was marked AIS 029.
This testing is generally used for commercial
vehicles.
V Roof Strength Test is used for similar test as rear wall
strength test.
V Frontal Impact Test is conducted to check the
strength of frontal portion of vehicle in case of head
on collision thereby assuring the safety of occupants.
V MCS Endurance Testing is used for cold testing
conditions inside the huge refrigerator for certain
duration.
V 4 Ball EP Tester technique is used to test the
performance of oils and lubricants under extreme
pressure conditions.
V Flash points were also determined using devices such
as automatic flash point tester ,Cleveland open tub,
Pensky Marten flash point tester ( for greases).
V (eather U meter was the device which is so
designed to simulate the outside weather conditions
and study its impact on the paint of the body panels.
V 1 year outside weather 21 days inside the tester are
equivalent.
V The Bajaj plant is divided into following shops:
V Aluminium shop.
V Steel shop.
V Engine shop.
V Vehicle body shop.
V Here at Bajaj Chakan plant daily 4000 units are
assembled.
V Three separate flexible conveyors for 150 cc and 180
or above cc bikes.
V Engine shop which adopts the cellular manufacturing
technique.

V After checking the precision and geometrical

accuracy of components the engine assembly occurs
which is then sent forward to the vehicle body shop.

V zero emission plant