International Journal of Innovative Technology and Exploring Engineering (IJITEE)

ISSN: 2278-3075 (Online), Volume-9 Issue-2, December 2019

Process Design and System Layout for an

Automobile Manufacturing and Assembly Plant
D. Phanindra Kshatra, S. Akhil, Ch. Uday Kiran, Ch. Yaswanth, M. Vineeth

Abstract: The Automobile is the most complex product, and the Due to these global concerns, most of the Original
development of a vehicle will take years of Research and Equipment Manufacturers (OEM's) are shifting the
Development (R&D) starting from designing, analyzing the manufacturing scenario where they concentrate only on core
product structure from sub-levels, building prototypes, testing the
prototypes, finalizing the vehicle to manufacture. It is also
components of the Automobile in-house and outsourcing
essential to find the correct suppliers to manufacture the most of the Automobile components to the reliable vendors
components, parts for the vehicle, assembly of all these to the and suppliers depending on their availability [3].
vehicle, and go through examination and analysis of various These OEM are concentrating mostly on R&D functions
stages of the processes in building the vehicle, and it is a herculean and manufacturing critical, value-added, technologically
task. With the increase in competitiveness in the Automobile advanced operations of high capital investments in-house and
industry, the Original Equipment Manufacturers (OEM’s) want to leave the rest to vendors and suppliers [3].
reduce their investments in manufacturing, keeping core In the Automobile industry, there is a lot of
competencies of R&D within the industry, and outsourcing
remaining functionaries to Tire companies. The main goal of this
manufacturing processes that happen to start from the
paper is to illustrate the step by a step manufacturing process that selection of different materials for the requirement of the
is needed to produce an Automobile. And explaining each step that Automobile [5]. People in the Automobile industry will have
takes the Automobile from sheet metal to complete product, this a lot of research going on the range and designing of a single
helps to understand the process chain, logistical and distribution component [4]. The present-day industry does not
network that an Automobile follows throughout its Product Life compromise on the aspect of the quality of its products [4] by
Cycle (PLC). maintaining a benchmark standard to sustain in the market [5].
In case of selection of material for the chassis, the R&D
Keywords: Manufacturing, System, Automotive, Stamping,
department of any Automobile industry will carry on different
BIW, Painting, Final Assembly
kinds of analysis for the chassis by considering different
materials into considerations [5]. One of the fewer weight
I. INTRODUCTION
materials available in the market is aluminium [5]. They will
Automobile Industry is one of the most complex and be the diverse composition of aluminium is possible; the
most dynamic industries in the engineering division, and it is behaviours of these materials will vary [4]. So, the suitable
the engineering marvel created by humankind. In recent years material will be taken into the consideration of design by
there is an increase in demand in the industry due to fierce Research and Development engineers [5]. Aluminium is used
competition, product life cycle change, and an increase in only for high speed and sports vehicles due to its cost factor.
customer demand [1]. With faster growth in the sector, But by using aluminium, it reduces the weight of the
Automobile industry's major issues concerned with Automobile, and thereby it reduces the load on the prime
customers' need for variety, variants, design stylings, safety, mover. It will directly impact the overall Efficiency of the
comfort, and within the industry's internal problems related to Automobile [5].
Elimination of Waste in processes, Process Efficiency, And after the selection process is over, we will again
Manufacturing Efficiency and improvement in Overall make the prototype of the BIW or Chassis, and we will still do
Equipment Effectiveness (OEE). the analysis for the prototype and will observe the results[7].
In our Automobile, we also involve FMS systems for the
mobility of the components or raw materials of the industry.
Will reduce a lot of random times in the industry and thereby
Revised Manuscript Received on December 30, 2019.
increasing the overall Efficiency of the Automobile industry
* Correspondence Author
D.Phanindra Kshatra*, Department of Mechanical Engineering, [6]. Even in the welding process, which is a significant part of
Koneru Lakshmaiah Education Foundation, Vaddeswaram, Vijayawada, the joining Process in the Automobile industry will be
India, [email protected] undergoing different tests to know the strength of the weld
S. Akhil, Department of Mechanical Engineering, Koneru Lakshmaiah and which type of welding process will have a better life [8].
Education Foundation, Vaddeswaram, Vijayawada, India.
Ch. Uday Kiran, Department of Mechanical Engineering, Koneru
Lakshmaiah Education Foundation, Vaddeswaram, Vijayawada, India.
Ch. Yaswanth, Department of Mechanical Engineering, Koneru
Lakshmaiah Education Foundation, Vaddeswaram, Vijayawada, India.
M. Vineeth, Department of Mechanical Engineering, Koneru
Lakshmaiah Education Foundation, Vaddeswaram, Vijayawada, India.

© The Authors. Published by Blue Eyes Intelligence Engineering and

Sciences Publication (BEIESP). This is an open access article under the
CC-BY-NC-ND license http://creativecommons.org/licenses/by-nc-nd/4.0/

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Blue Eyes Intelligence Engineering
DOI: 10.35940/ijitee.B6435.129219
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Journal Website: www.ijitee.org
 Process Design and System Layout for an Automobile Manufacturing and Assembly Plant

II. STEP-BY-STEP AUTOMOTIVE punches to cut the sheet metal into required shapes [9], [10].
MANUFACTURING PROCESS: The stamping department is responsible for the production of
a complete vehicle body [9]. Stamping It involves a metal
cutting process where the coils of metal cut into uniform
dimensions into smaller sheets, and particular shape formed
with the help of different presses for different components for
an Automobile Body [9]. It is a forming process in which
extreme pressure is applied on the sheet metal blank within its
plasticity limit to obtain the desired shape. The main reason
for the stamping process is to produce parts of any dimension
and shape out of sheet metal. [10]
The stamping department is responsible for making
Automobile Body parts like the bonnet, hood, doors, roof, etc.
It consists of various sheet metal operations like blanking,
coining, hemming, flanging, embossing, etc. Every part may
not undergo every process in stamping, as it depends on the
complexity of the piece. Stamping operations performed in
various stamping stations that use a die and a Mechanical
press of a specific part for forming the desired shape [11].
Figure 1: Major Departments and workflow for
A Stamping department produces the car’s complete
Automotive Plant (2)
external shape. An Automobile requires around 40 to 50
significant panels, and most of them are produced in house
Major departments that involve in Automotive Manufacturing
and don't want to outsource because of the defined geometry
are Stamping Department, Body-In-White Department,
and quality of the Automobile [12], [13]. Most of the smaller
and/or Chassis Department, Foundry Department, Painting
sheet metal components manufactured by Tire Companies
Department, Manifold Department, Final Assembly
[12], [13]. To produce these panels, it will take 100- 200 dies
Department [2].
and change-over of these dies, depending on the variant of the
vehicle, which is the most essential and crucial Process in
III. LIMITATIONS
stamping [12], [13].
In this paper, the discussion is about the entire outline of Stamping Process is divided into two parts 1) Material
the plant layout for the Automobile industry and divided into Production Process and 2) Panel Production Process. The
two-part, one is the main process flow from stamping to the Material Production Process starts from the wounded coil till
final assembly, and the second part is foundry. The foundry the blanking press where the coil transferred from de-coiler,
treated as the secondary part of the Automobile industry, and feeder, strip-wash, and lubrication and cuts into panels by dies
again, it is brought back into the main process flow in the in Blanking Processes. In Panel Production Process, Press
assembly operation. So, for the simplified analysis, this paper Machines are used to produce the designed panel components
is excluding the foundry part and mainly concentrating on the of required shapes and sizes [12], [13].
main process flow of the Automobile industry. The flowchart describes the flow of different operations
sequentially in the stamping process. The flowchart is drawn,
The Assumptions and/or Limitations that considered in the keeping in view of every all the parts of a car body. So every
deriving process flow of the Automobile industry are operation may not be performed on the sheet metal blank.
1. The chassis that discussed in this paper for the
analysis is a monocoque chassis.
2. The most parts and/or components of an Automobile
manufactured with in the industry itself.
3. The analysis was done by neglecting small parts of the
Automobile.
4. This paper is through the outline of the Automobile
industry.
5. This paper does not follow any single Automobile
industry or model of vehicle.
6. This process flow and specifics of the production
process may vary from one industry to another.
7. This paper only reflected the main process flow and
had excluded the foundry part of the industry.

IV. DEPARTMENT WISE PROCESSES:

Figure 2: Sheet Metal Panels for Car Body ()
A. Stamping Department
The press shop/stamping is a department in the
automotive industry and is the foremost Process in the
manufacturing of an Automobile production and use dies and

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Blue Eyes Intelligence Engineering
DOI: 10.35940/ijitee.B6435.129219
441 & Sciences Publication
Journal Website: www.ijitee.org
 International Journal of Innovative Technology and Exploring Engineering (IJITEE)
ISSN: 2278-3075 (Online), Volume-9 Issue-2, December 2019

Hydroforming has many applications like automotive engine

cradle, camshafts, exhaust pipes [14].
B. Body-In-White Department
BIW standards for Body-In-White. BIW is a stage in
Automobile manufacturing. Here the complete body shell of
the Automobile is welded and structure from all the sheet
metals formed into sub-assemblies
The assemblies of all the Frames and Panels of both Structural
Figure 3: Stamping Department (3), (4) Components,
* Processes depend on the type of body parts. as well as the exterior parts of an Automobile combined with
homogeneous materials, form car body structure. BIW does
The processes involved in the Stamping Department are not include doors, engines, and other moving parts.
1. Coil Transfer Handling
2. De-Coiler Components of BIW are
3. Feeder 1) A-Pillar
4. Strip Washing 2) B-Pillar
5. Adjustments and Lubrication 3) C-Pillar
6. Blanking Press 4) D-Pillar (Depends on Car Variant)
7. Material Feed 5) Roof Frame/ Roof Structure / Roof Panel
8. Tool Change-over (or) Tool Set-up 6) Floor and other Panels
9. Drawing 7) Front and Rear Longitudinal Beam
10. Forming 8) Rocker/ Side Sill
11. Re-Strike 9) Dashboard Mounting Panel
12. Piercing 10) Hood (Frame and Panel)
13. Flanging 11) Front Fenders (Right and Left)
14. Hemming 12) Rear Fenders (Right and Left)
15. Trimming 13) Decklid/ Trunk lid/ Tailgate (Frame and Panel)
16. Scrap and Recycling 14) Doors (Frame and Panel)
17. Panel Measurements according to dimensions 15) Dashboard Mounting Panel
18. Finished part removal 16) Cross Member
19. Material Transport and Storage 17) Fire Wall
18) Floor, Seat and Boot Pan
 Firstly, the sheet metal coil fed through a de-coiler to
the strip washing plant. After washing, necessary
adjustments and lubrication did.
 Depending on the size of the body panel, the blanking
of the strip done to the required dimensions.
 The blanked sheets fed to the stamping press, and the
punching done with the appropriate die.
 Other operations like hemming, flanging, piercing,
restrike are done if the required product has a
complex shape. Trimming is done to remove the
excess material is present in it.
 It is to ensure the precision of the part that had Figure 4: B-I-W Department (3), ()
produced, inspection will be done on it, and the
approved parts sent to the inventory storage. BIW consists of a different kind of joining Processes
 The scrap produced during this stamping process like welding, soldering, brazing, adhesive bonding and
recycled for reusing the material. mechanical joints we use all this joining Process according to
 Every part will not require all operations. So, the need of the components that we join [15]. In BIW, one can
changing of tool or die will be done for the required come across different types of components with different
parts. shapes. And there is a material property of each material vary
An Automobile body may contain more than 1500 stampings, that from the other, and the metallurgical processes might also
and nearly 60-70% of metal parts of an Automobile made by need to join dissimilar metals that are used to join different
plastic forming [12], [13]. components together and derive the desired shape [15].
Hydroforming is a newly constituted technology in the In BIW, the most commonly used material for the
automotive industry as it offers distinguished advantages manufacturing of the components is steel, and there will be
compared to conventional manufacturing processes. In this different compositions of steels that we use in the
Process, fluid pressure is applied to the metallic blanks to Automobiles according to usage and the loads that applied to
form desired component shapes. The amount of scrap the members [16].
material observed for the conventional stamping process is
20-30%, whereas, for hydroforming, it reduced to 0-10%.

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Blue Eyes Intelligence Engineering
DOI: 10.35940/ijitee.B6435.129219
442 & Sciences Publication
Journal Website: www.ijitee.org
 Process Design and System Layout for an Automobile Manufacturing and Assembly Plant

In BIW, the hot-stamped steel is used up to 30% of the might have some buffer time to it because the framing is
total material that we use in BIW [16]. The main reason for dependent on the toy tab [18], [19].
the usage of hot-stamped steel is that it has relatively low
weight when compared to most of the steels, and it also has Toy Tab: - Toy Tab can also be called as main body
more crash resistance and high strength at a very low cost station because the Underbody and the sub-assemblies of
[16]. The HSS (High-Speed Steel) is the major material used front and rear are taken together and joined here [18], [19].
in the structural components of the BIW [17]. The weight of The toy tab is a dependent process because it mainly depends
any material and its strength plays an important role in the on the underbody assembly and sub-assemblies [18], [19].
selection of the material. Most of the panels and components The further step of the toy tab is the framing Process. The toy
in the BIW will be coming from the Stamping process, where tab prominently uses welding operation and some hemming
we will convert the sheet metal rolls into different panels and operation. All these operations are carried out by robots [18],
components. At an average, the BIW will have 2206 weld [19].
spots involved, the majority part of this welding process is to
join the pillar parts of the Automobile chassis [17]. The Framing: - In framing, we will get an almost integrated
maximum part of the welding operations done by robots [17]. outlook of the chassis. The parts that assembled in this
framing process are the toy tab and side panel assemblies and
The BIW in our will be mainly having five major the roof of the Automobile [18], [19]. All the parts of the
assembly stations. They are listed below framing process assembled on the toy tab [18], [19]. On the
1. Under Body toy tab, the assembly will be on the side panels of the
2. Side panel assembly (exterior & interior) Automobile, and then after the roof of the Automobile is
3. Toy tab assembled on the panels [18], [19]. This process is the most
4. Framing important step in the BIW to get an integrated chassis or body
5. Panel line [18], [19]. And this body after framing will be sent for a
6. Assembly [15]. manual inspection for the checking of the dents in the body
and this framed body is sent to the piercing of any required
In the Automobile industry, we will maintain storage for holes on the frame for further processing [18], [19].
every component to reduce the entire manufacturing time in
the industry [16]. So, in our design of BIW, consideration of Panel line: - This is the final stage of the BIW, where we
storage for every component that is coming out from the assemble the fenders, liftgate, and fuel door. So, this panel
Stamping shop and directly takes out components that need to assembly will have all the entire part of BIW except the doors
assemble from the storage only [17]. of the Automobile [18], [19].

In the BIW process plan that we have adopted, we can Assembly: - This final assembly in BIW will mainly have
clearly say that the Process in Underbody and side panel the assembly of the doors, hood, and tailgate, trunk lid
assembly (exterior & interior) are independent Processes and [18],[19]. By this assembly, the entire Process of BIW
can be done simultaneously with any interference. In contrast, completed, and this complete assembly is taken out for the
the toy tab is dependent on the Underbody and the finishing process. Then there will be a final inspection for
sub-assemblies of the front and rear. So, by this, we can say each assembly, and then the certified body will only be
that BIW consists of both independent and dependent process allowed to the next department, i.e., Paint shop [18], [19].
flow [18], [19].
C. Painting Department
Under Body: - Under Body assembly, majorly consists of
3 parts that are the front floor, rear floor and engine
compartment this will make a platform for the entire BIW and
each component is assembled on the Underbody [18], [19].
And the type chassis that we are taking into the consideration
for the entire layout is a monocoque chassis, where we will
not find and ladder structure to assemble the BIW [18], [19].
So, in our analysis of monocoque chassis, the Underbody will
act as a basic structural frame to assemble the components
[18], [19].

Side Panel Assembly: - This side panel assembly consists

of both outer and inner panels like in Underbody. They will
also come from the stamping process. They will be taken from
Figure 5: Painting Department (3), (14)
the store directly. This inner panels will also be housing the
guideways for the electrical lining. In contrast, the outer
Paint application is the most required process for vehicle
panels will be like smooth finished work without any
production, and it is not exclusively done for covering but
penetrations on them [18], [19]. This panel assembly will
also for the safety of body surface,
mainly have the pillars of the Automobile like A pillar, B
pillar, and C pillar according to the design of the Automobile
this pillar may vary [18], [19]. This side panel assembly will
be directly going to the framing process, and this assembly

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Blue Eyes Intelligence Engineering
DOI: 10.35940/ijitee.B6435.129219
443 & Sciences Publication
Journal Website: www.ijitee.org
 International Journal of Innovative Technology and Exploring Engineering (IJITEE)
ISSN: 2278-3075 (Online), Volume-9 Issue-2, December 2019

it also increases the visual interest by adding the shades as Inspection and Storage:
well as the shine and imperative offering focus [20], [21]. Car After the last spray coating operation, the final steps are to
paint will be paint used on cars for both embellishment and inspect the quality of the painting operation, a thorough check
security reasons [20], [21]. The mostly used water-based for every part of the body done, and this Process is done either
acrylic polyurethane lacquer paint is presently utilized paint manually or in automated testing condition. Only after
for the painting process is done after the body of the vehicle is thorough and rigorous inspection, the vehicle sent to
assembled [20], [21]. The painting process is done to give assembly. Otherwise, the vehicle has the repeat all the
more attraction to the vehicle, good appearance, and to processes again till the final quality standards are met, and the
provide a protective layer against the corrosion as well as the car body is sent to Storage / Assembly department [20], [21].
weathering. There are main four major process involved in the
D. Final Assembly
paint shop [20], [21]. They are 1. Pre-treatment, and
Electrodeposition or E-Coating, 2. PVC sealing, 3. Primer Assembly line usually consists of many numbers of
coat painting, 4. Topcoat painting [20], [21]. workstations, and it is important where all the components of
the B-I-W and Mostly, the Powertrain of the Automobile are
Pre-Treatment: assembled sequentially in a fixed pattern [22].
After completion of B-I-W, it is important to clean the body
surface to get rid of all the deposits obtained during different In this assembly process and/or department, most of the
operations, and this cleaning process is done through three work carried out manually, and the workers move along with
dipping processes, 1. Degreasing, 2. Conditioning, 3. the conveyor to complete the task at that station. They will
Phosphating. After cleaning, the Pre-Treatment process done scale back to the initial position to work on the next
where it acts as a primer to bond onto the metal [20], [21]. Automobile in the line [22].

Electrodeposition or E-Coating:
The next Process is Electrodeposition or E-Coating, where
this Process is done to prevent the metal body from corrosion,
this Process is done and depends upon various types of sheets
that are used for car body materials [20], [21].

Rust Proof Materials: PVC Sealing:

PVC is Polyvinyl Chloride Sealing and applied to doors,
trunk, hood, dashboard, and all the exterior and interior joints.
And also used mostly for Underbody to achieve noise-proof
platform and to reduce the vibrations that occur in B-I-W, this
also helps the Underbody from rust and corrosion and
chipping protection [20], [21].

Primer:
After PVC Sealing the next step is applying primer to the Figure 6: Final Assembly
body, and it is of three types 1) Powder Type, 2) Water-borne,
3) Solvent-borne, Primer helps as an adhesive between the After the painting process completed, the B-I-W will move to
E-Coating and Topcoat providing the corrosion protection the final assembly department. In the first station, the primary
and appearance of the vehicle [20], [21]. operation is to dis-assemble the doors from the rest of the
body, dashboard, and other instrumentation panels are fixed.
Topcoat: This process is completed manually by the workers. The next
The next step in this process is topcoat, and it has two steps station is the most important, and it is the assembly of B-I-W
a) Basecoat and b) Clearcoat to Powertrain, which is termed as marriage station, here the
a) Basecoat: The Basecoat is usually for the primary body and powertrain meet together. A lot of many assembly
coloring pigment for the vehicle [20], [21]. works are carried out, and this station the Automobile gets its
b) Clearcoat: The Clearcoat is usually for the complete structure and final appearance, in the next station's
protection of UV light, environmental effects, and wheels, seats. Finally, the doors installed to the Automobile,
provide a smooth finish for the vehicle [20], [21]. which previously removed for assembly process to the
Automobile and all the necessary tests for the engine, chassis
Spray Coating: did, and a thorough final inspection is conducted to the
The last and final process is Spray Coating, where tiny vehicle and stored in the warehouse for distribution around
droplets of paint are absorbed in a continuous gaseous phase the world [22].
that applies to the parts and complete body. This Process
gives the fine finish of the paint, and the appearance furnished V. RESULT AND DISCUSSION
with the quality look. After this process, the heat generation In this paper, the complete manufacturing of the main
process is done for sticking the paint to the body, while this automobile line had discussed,
Process continuous other small parts form the storage is also
in Process of the above coatings and join in another line. They
both get assembled, and the painting process is completed
[20], [21].

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 Process Design and System Layout for an Automobile Manufacturing and Assembly Plant

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Published By:
Retrieval Number: B6435129219/2019©BEIESP
Blue Eyes Intelligence Engineering
DOI: 10.35940/ijitee.B6435.129219
445 & Sciences Publication
Journal Website: www.ijitee.org
 International Journal of Innovative Technology and Exploring Engineering (IJITEE)
ISSN: 2278-3075 (Online), Volume-9 Issue-2, December 2019

24. D. Phanindra Kshatra et al., A Methodology to Adapt and Understand a

Manufacturing System and Operations using Discrete-Event
Simulation, International Journal of Engineering and Advanced
Technology (IJEAT), ISSN: 2249 – 8958, Volume-8 Issue-6, August
2019.

AUTHORS PROFILE

Mr. D. Phanindra Kshatra, working as Assistant

Professor in the Department of Mechanical Engineering
of Koneru Lakshmaiah Educational Foundation of
Andhra Pradesh state in India. He has published many
international journals in various reputed Journals. His
area of interest is in Discrete Event Simulation, DES in
Lean, Lean Flow, Kanban Systems, and Simulation methodologies. At
present, his area of research is going on Discrete Event Simulation for
Automobile Manufacturing.

S. Akhil is an IV Year, B-Tech Mechanical Engineering

Student at Koneru Lakshmaiah Educational Foundation,
Vaddeswaram, Guntur (DT)

Ch. Uday Kiran is an IV Year, B-Tech Mechanical

Engineering Student at Koneru Lakshmaiah Educational
Foundation, Vaddeswaram, Guntur (DT)

Ch. Yaswanth is an IV Year, B-Tech Mechanical

Engineering Student at Koneru Lakshmaiah Educational
Foundation, Vaddeswaram, Guntur (DT)

M.Vineeth is an IV Year, B-Tech Mechanical

Engineering Student at Koneru Lakshmaiah Educational
Foundation, Vaddeswaram, Guntur (DT)

Published By:
Retrieval Number: B6435129219/2019©BEIESP
Blue Eyes Intelligence Engineering
DOI: 10.35940/ijitee.B6435.129219
446 & Sciences Publication
Journal Website: www.ijitee.org