AUTOMOTIVE ASSEMBLY PROCESSES

John L. Evans, Ph.D.

AUTOMOTIVE SUPPLY CHAIN

• SHEET METAL

• POWERTRAIN (ENGINE & TRANSMISSION)

• INTERIOR (SEATS, DASH, CARPET)

• ELECTRONICS

• LIGHTING

• TIRES & BRAKE SYSTEMS

• COOLANT SYSTEM

• CHASSIS

• GLASS

REGIONAL AUTOMOTIVE SUPPLIERS

AUTOMOTIVE FACILITIES

• 200,000 to 700,000 + units per year

• $1 - $3 Billion Investment

• 10 – 20 Miles of Conveyors

• 250+ Robots (Welding, Painting, Sealing)

• $10 Million per day – Incoming Materials

• 250+ Acres Site Requirements

• $500,000 - $1,000,000 per month Utilities

MATERIALS FLOW

• Process Must Match– Powertrain (Engine, Transmission)

– Seats

– Exterior Styling (Grill, Trim, Color)

– Features (Audio, Computer, RKE)

– Glass

• JIT Delivery System

• Material AS/RS

• Quality Inspection

http://www.workhorsecc.com/tours/virtual.asp

ENVIRONMENTAL CONTROL

• PAINTS

• VEHICLE WASH

• COOLANTS

• SEALANTS

• GASOLINE & OIL

• AIR CONDITIONING SYSTEMS

• EXHAUST

ENGINE ASSEMBLY

ASSEMBLY AUTOMATION

INTERIOR ASSEMBLY FEED

TIRE ASSEMBLY FEED

CAR ASSEMBLY ROUTE

AUTOMATIC WELDING

ASSEMBLY TRACKING

VEHICLE TRACKING

• JIT System for Parts Delivery

• Material Flow Must be in Order

• Part Availability Must be Checked Early in Process

• Vehicle Process Problems Must Consider Materials Flow

• System Quality Must be Monitored Throughout Operation

• Mercedes-Benz U.S. International, Inc. - Home of the M-Class