argentum auto technical presentation
Transcript of argentum auto technical presentation
This presentation will give you – Overview of Production Facilities – Plant Capacity/Production Range/ Localization Status– Plant production History– Press Shop– Body Shop– Paint Shop– Assembly Shop– Plastic Moulding & Paint Shop– Support Facility & Technical CentreEach Shop will give you detailed list of – Machine & Equipment List– Tooling– Process Flow for Matiz and Cielo Production– Components produced by Daewoo – Support Machines
Contents
Brief history of Daewoo Motors plant• Facility started by Toyota in 1985 as a Com. Vehicle plant.
• Daewoo added ETA, Press Shop, Aluminum Die Casting, Plastic Molding and Power Plant in 1998.
• Daewoo manufactured 3 models in this facility:
Cielo in 1995, Matiz in 1998 and Nexia in 1999
• Ownership of the plant moved to a consortium of banks and as a result it remained out of operation for 4 years.
• Plant was maintained on a daily basis by a company specialized in engineering and maintenance
Argentum Auto
FACILITIES
CAR MANUFACTURING FACILITIES
PRESS SHOP BODY SHOP
ASSEMBLY SHOP PLASTIC PAINT & MOULDING SHOP
PAINT SHOP
ENGINE & TRANSMISSION MANUFACTURING FACILITIES
ENGINE SHOP TRANSMISSION SHOPALUMINIUM DIE CASTING SHOP
FACILITIES
UTILITIES
POWER GENERATION COMPRESSED AIR & HOT WATER GENERATION EFFLUENT TREATMENT
PLANTR&D
VARIOUS TEST LABORATORIES ( EMISSION, ENGINE, VEHICLE, CHEMICAL & GENERAL )DRAWING MANAGEMENT & DESIGN ROOM
n CAR PLANT
a. CAR BODY SHOP : Sq. m
b CAR PAINT SHOP : Sq. m
c. CAR ASSEMBLY SHOP : Sq. m
d. PLASTIC PAINT SHOP : Sq. m
: Sq. m
n PRESS SHOP : Sq. m
n PLASTIC MOULDING SHOP : Sq. m
n KD WARE HOUSE : Sq. m
n CIELO HEMMING SHOP Sq. m
TOTAL COVERED AREA : Sq. m
38,025
3,800
17,340
1,834
7,540
67,859
3,120
TOTAL AREA ( Car Plant )
8,340
11,635
14,250
Car Plant Over View – Covered Area
DELHI DADRI
ALDC
POW
ER
CANT
EEN
PRESS SHOP
DELIVERY YARD BONDED W/HOUSE
UTILITY CENTER
TECH-CENTER
KD WAREHOUSE
CVD
A/S PARTS
CENTER
PROPANE STORAGE LPG STORAGE
YARD
BODY SHOP
PAIN
T SH
OP
ASS
'Y S
HO
P
HEMMING
PLASTIC PAINT & BUMPER SHOP
CKDSTORAG
BUS PARKING
TEST TRACK
ENGINE & TRANSAXLE SHOP
G R E E N B E L TG R E E N
B E L T
GREEN BELT
GREEN BELT
GREEN BELT
GREEN BELT
GREEN BELT
N
Gate#1Gate# 2Gate#3
Gate #4
ETP
W/HSE
INCINATOR
HFO
DG R
OOM
HSD STORAG
CARSTORAG
MATERIAL
YARD
CANTEEN
DM WATER
ETP
DI WATER
SECURIT
Main
CAR PARKIN
Total Build Up Area : 191,720 sq.m (23%)
Total Land Area : 825,610 sq.m
Plant layout
Stagewise Process flow details : Car Manufacturing
BODY( Welding of parts )
PAINT( Painting of shell )
ASSEMBLY( Assembly of car )
PLASTIC( Plastic painting & Injection Moulding )
PRESS( Forming of parts )
INSPECTION( Inspection of car )
ENGINE / TRANSAXLE
POWER / UTILITY( Power , Compressed air, Water )
VENDOR PARTS
Process Flowchart – Car Manufacturing
3500 TTransferLine
2300 TTransfer Line
2400 TTandom Line
Press Shop
Pre Ass'y Under Body Main Body BIW Line Repair
Side Body Hemming Line
SubAss'y
Body Shop
PT & CED LineSealing and U/Coat.PrimerTop CoatPainted Body
Stock
Trim Line Chassis Line Final Line
Sub Ass'y
Assembly Shop
FinalInspection
ShowerTest C.S.Line Guage
Line
Inpection Line
Delivery ToMarketing
White BodyStockCoil
Paint Shop
Auto
Components
Process Flowchart – Car Manufacturing
Items
No of parts
% Contrib'n
No of parts
% Contrib'n
No of parts
% Contrib'n 32.43%
Total Number of
Parts
223
43.95%
255
22.35%
4783 TOTAL
230 93 155
48.12% 19.46% 32.43%
323
67.57%
57 57
55.29% 22.35% 22.35%
198
77.65%2
MATIZ
CIELO141
189
16.14%39.91%
PRODUCT NAME
98
43.95%
125
56.05%
IMPORT PORTION
Local Parts In - HouseS.No
36
P A R T S D E T A I L S
Total Localisation
Localization Status – Matiz & Cielo
IN- House Manufacturing – Body Parts
Total Parts ( No. )
Parts Details ( No.)
9
11
16
15
17
25
24
28
41
30.56
3 TOTAL
25.81
93
2400 Ton TANDEM LINE 44.09
2300 Ton TANDEM LINE
3500 Ton TANDEM LINE 30.11
25.00
2300 Ton TANDEM LINE
3500 Ton TANDEM LINE
2400 Ton TANDEM LINE
2300 Ton TANDEM LINE
26.32
29.82
43.86
44.44
3500 Ton TANDEM LINE1
2
PRODUCT NAMELINE NAME
CIELO 57
36MATIZ
2400 Ton TANDEM LINE
% Contribution
S.NoP A R T S D E S C R P T I O N
Total Parts ( No. )
Parts Details ( No.)
2
1
2
3
4
4
P A R T S D E S C R P T I O N
MATIZ
% Contribution
33.33
66.67
50.00
560.00
S.No
11600 Ton INJECTION MOULDING
CIELO
PRODUCT NAME
LINE NAME
3500 Ton INJECTION MOULDING
1600 Ton INJECTION MOULDING
3500 Ton INJECTION MOULDING
3
3 TOTAL
40.00
50.008
1600 Ton INJECTION MOULDING
3500 Ton INJECTION MOULDING
2
IN- House Manufacturing – Plastic Parts
PLANT CAPACITY
Normal Over-time
Total
1 OVERALL 17 95% 16.1 7.67 0 7.67 123 246 72,000
2 ASSEMBLY 17 95% 16.1 7.67 0 7.67 123 246 72,000
3 PAINT 16 95% 15.6 7.67 0.21 7.88 123 246 72,000
4 BODY 16 95% 15 7.67 0.53 8.20 123 246 72,000
5 PRESS 30 95% 28.4 7.67 0 7.67 218 436 127,000
WORKING Hrs PER SHIFT PRODN /
SHIFTS. No SHOP NAME EFFICIENC
YNET JPH
ANNUAL PRODN .
(Approx) (@293 Days )
OVERALL ANNUAL PRODUCTION CAPACITY* IS 72,000 Cars / Annum*
GROSS JPH
PRODN / SHIFT
( 2 Shift )
2.1
*ANNUAL PRODN. CAPACITY : 7.67 ( Working Hrs ) X 16.1 ( JPH ) X 293 ( Working Days ) X 2 ( Two Shift )
Plant Capacity
1995 ~ 1996 1996 ~ 1997 1997 ~ 1998 1998 ~ 1999 1999 ~ 2000 2000 ~ 2001 2001 ~ 2002 Total
9,117 17,537 5,102 4,173 1,552 705 112 38,298
0 0 0 0 0 0 0 0
9,117 17,537 5,102 4,173 1,552 705 112 38,298
0 0 0 4,342 32,796 31,905 7,980 77,023
0 0 0 0 1,207 1,578 70 2,855
0 0 0 4,342 34,003 33,483 8,050 79,878
Total
1995 ~ 1996 1996 ~ 1997 1997 ~ 1998 1998 ~ 1999 1999 ~ 2000 2000 ~ 2001 2001 ~ 2002
9,117 17,537 5,102 8,515 34,348 32,610 8,092 115,321
0 0 0 0 1,207 1,578 70 2,855
9,117 17,537 5,102 8,515 35,555 34,188 8,162 118,176
SUB TOTAL
S.No PRODUCT PRODUCT DETAIL
P R O D U C T I O N D E T A I L ( Year-wise )
S.No PRODUCT PRODUCT DETAIL
3TOTAL
( CIELO/NEXIA + MATIZ )
DOMESTIC
EXPORT
SUB TOTAL
P R O D U C T I O N D E T A I L ( Year-wise )
2 MATIZ
DOMESTIC
EXPORT
SUB TOTAL
CIELO / NEXIA1
DOMESTIC
EXPORT
Car Production History
Engine , Transaxle&
Aluminum Die Casting Plant
l BUILDING AREA COVERED
p ENGINE - 18,200 Sq. METER
p TRANSAXLE - 20,800 Sq. METER
p AL. DIE CASTING - 6,400 Sq. METER
p TOTAL - 45,400 Sq. METER
Engine Transaxle and Al Die-casting –Plant Area Details
Engine & Transaxle plant with an annual capacity to manufacture 400,000 engines and transaxles for passenger cars.
PIM : Engine & Transaxle Plant
• Capacity to manufacture 400,000 units of engines and transaxles annually
• Transfer lines for Cylinder Block of 1.5L/1.6L capacity and Cylinder Head
• Flexible lines for Crankshaft (450MM), Camshaft (430MM) and Con Rod (Fractured-Alfing line)
• Automated assembly and test lines with 18 test cells.
PIM : Engine Plant
ENGINE T/A SHOP LAYOUT
A MONIA R OOM
MAIN SHAFT
GEA
R-3
HEL / G
ENGINE & T/A DELIVERY STOCK
ENGINE TESTING
ENGINE ASSEMBLY
HEAT TREATMENT
C/ CL-5
T/A TESTING
DIFF
.-HO
USIN
G LIN
E
SHIF
T FO
RK L
INE
BRG
. PLA
TE L
INE
T/A
-CAS
E LI
NEDYNAMO TESTING
DG/B
-3
T/A
ASSE
MBL
Y LI
NE
VEND
OR
PART
S
CON-
ROD
LINECY
LIND
ER B
LOCK
LIN
E
& BE
ARIN
G C
AP L
INE
CRAN
K SH
AFT
LINE
CYLI
NDER
HEA
D LI
NE
CAM
SHA
FT L
INE
( HAR
D )
GEA
R-1
GEA
R-4
GEA
R-5
C/ CL-5
GEAR-5
GEAR-5
GEAR-5TOOL SHAR
P
HEL / GEAR
C/ CL-3&4 GEAR-1
GEAR-2
SH/SL-5
SH/SL-3&4
SL/GEAR
REV/GEAR
RAW MATERIAL
COOLANT SYSTEM
DG/B
-4DG
/B-5
GEA
R-2
REV/G
INPUT SHAFT MAIN SHAFT
INPUT SHAFT
ELEC. CONTROL ROOM
ELE
C. C
ON
TRO
L
ROO
M
TOIL
ET
SPARE PARTSMAINT.
MECH. & ELEC. DI
SPLA
Y
GRI
NDIN
G
WHE
EL
STO
RAG
E
TOOL CRIB TOOL SHARPENING MEASURING ROOMSHAVING CUTTER
AIR.-COND.
MAT'L
WELD
TOOL ROOM &WORKSHOP
TOILET
JIG BORG.
LAB
GAU
G
POWER STAT. CENTRAL COOLANT SYSTEM ( C.C.S.) RECEVING
DOCKMAT'LCNT'L COOLANT SYSTEM TOILET POWER
STAT.ELECT.
UTY ROOM
Process Flow Chart – Engine T/A
RAW MATERIAL HEAT TREATMENT
ISO THERMAL SOFT ANNEALING MACHINING
( GEARS, SHAFTS, SLEEVES, CLUSTERS)
T/AXLE CASE INPUTFROM ALDC
ASSEMBLY
GENERAL MACHINING
TESTINGASSEMBLED
T/ AXLEHARD
MACHININGTRANSAXLE SHOP
CAM SHAFTCYL HEAD
CRANK SHAFTCYL BLOCK
BEARING CAPCON ROD
CYL HEAD INPUT
FROM ALDC
ASSEMBLYENGINE SHOP
TESTINGASSEMBLED
ENGINEMACHINING
D16 Transaxle plant
• Completion date Sep. 1997• Start of Production Mar. 1998• Production capacity 60 JPH • Production Model
D16 with Axle ratio 3.722C4.176W3.944W4.176M
• Cumulated production volume : 68,972 units
D16 Transaxle plant
• In-house machining : Total 23 items
Description Kinds Description Kinds
Speed Gear 5 T/A Case 1
Gear Cluster 2 Bearing plate 1
Shift Sleeve 3 Differential hsg 1
Dog body 3 Shift fork 3
Shaft 2
Helical/Reverse 2
D16 Transaxle plant
• Special features - Machining line : Machines with highly reputation
Kind of Machine MakerLathe/SPM DHI
Hobbing machine Kashifuji
Shaping machine Lorenz/Karats
Shaving machine Hurth/Kanzaki
Deburring machine SU-Samputensili
Sorting machine Shinsei
Cyl./Angular grinder Toyoda
Combination grinder Reinecker/Supfina
Internal grinder Okuma/Toyo
Transfer machine Sakurai/Enshu
- Assembly line : Palletized Conveyor system- Test line : Testers to check noise and shiftability
Function tester 2 setsAudit tester 1 set
- Heat treatment line. Iso-thermal anealing furnace for raw material. 3 sets of Continuous Carburizing line. 2 sets of Tempering furnace. 5 sets of Batch type Carburing furnace. Shot peening and shot blasting machine. Full sets of metallurgical lab.
D16 Transaxle plant
D16 Transaxle plant
- Non production facilities1) Tool Resharpening
. Shaving cutter re-grinder (Hurth)
. Broach cutter re-grinder
. Hob. Shaper re-sharpeners
. Grinders for micro bit, gun drill and other tools2) Tool Room
. CNC Jig borer and Jig master
. Shaper, Machining centers
. Surface/External/Internal grinders3) Measuring Room
. 3-D CMM, Gear measuring m/c
. Profile/Roughness/Roundness tester
. Microscope/Sterocope/Film processor, etc
D16 Transaxle plant
LAYOUT - Transaxle Shop
l
l
l
l l l l l l l l l l l l l l l l l#
l l l l l l l l l l l l l l l l l#
n
Speed Gear 1st ( Soft )Gear Cluster 3&4th ( Soft )
Helical Gear ( Soft )
Gear Cluster 5th( Soft )
Speed Gear 5th ( Soft )
Speed Gear 4th ( Soft )
Speed Gear 3rd ( Soft )
Helical Gear ( Hard )
Input Shaft ( Hard )
Spee
d Gea
r 5th
( Hard
)
Spee
d Gea
r 3rd
( Hard
)
Spee
d Gea
r 4th
( Hard
)Sp
eed G
ear 2
nd ( H
ard )
Spee
d Gea
r 1st
( Hard
)Do
g Bod
y 4th(
Soft)
Dog B
ody 3
rd(So
ft)
Dog B
ody 5
th(So
ft)
Bearing
Case
Test Line
TA Ca
se
Beari
ng Pl
ate Li
ne
Differ
ential
Housi
ng Li
ne
Shift F
ork Lin
e
Shift
Sleev
e ( Ha
rd )
Main
Material
Welding Zone
Reverse Gear ( Hard )
Main Shaft ( Soft Line )
Input Shaft ( Soft Line )
Gear cluster 5th ( Hard )
Speed Gear 2nd ( Soft )
Shift Sleeve 5th ( Soft )
Shift Sleeve 3-4th ( Soft )
Sliding Gear ( Soft )
Reverse Gear ( Soft )
Tool & Work Shop
Toilet
Jig Boring Room
Measuring
Metall
urgy
Gear Cutter
Grinding
Air Con
Tool Sharpening ShopTool Crib
Parts Storage
Grinding
Locker
TA ASSEMBLY
Heat Trartment Shop
0160
120
Aluminum Die Casting Plant with High Pressure and Low Pressure Die Casting Facility having an annual Melting capacity of 37,500 tons of Aluminum Alloy.
PIM : Aluminum Die Casting Plant
ALDC Shop Layout
ALDC SHOP LAYOUTJ
H
G
F
E
D
C
B
A 10 10 M 20 20 M 30 20 M 40 30 M 50
DIE M
AINTE
NANC
EMELTING FURNACE ( LPDC )
LPDC
CAST
ING M
/CS
CORE
BLOW
ING
HEAT
TREA
TMEN
T
FINISH
LINE
PARTS STORAGE
ALDC
LABO
RATO
RY
ALDC
OFFIC
E ( M
EZZA
NINE
)
MELTING FURNACE ( HPDC )
HPDC
DIE C
ASTIN
G MA
CHINE
S
DIE M
AINTE
NANC
E
DIE ST
ORAG
E
PART
S STO
RAGE
10M
Al Die casting plant
Description Machine Name Maker Q’tyHPDC Die casting machine UBE 3(T/A Case) Melting furnace
Holding furnaceCasting die and others
LPDC Casting machine Isuzu 8(Cyl. Head) Melting furnace
Core blowing machineCore drying furnaceFinishing lineT-4 Heat treatmentDie and others
ALDC – Test Facility
n ALDC TEST FACILITY
p LEAK TESTERS :- 2 NO.s ( MAKER : M/S JUNG POONG KOREA)
PURPOSE OF THIS TEST IS TO CHECK THE LEAKAGE OF CYL. HEAD OIL/ WATER JACKET & COMBUSTION CHAMBER FOR DEFECT FREE CASTING
p X - RAY TESTER :- 1 NO. ( MAKER :KEUG DONG KOREA )
PURPOSE OF X - RAY IS TO DETECT ABNORMALITIES IN WALL THICKNESS OF TRANSAXLE CASE TO ENSURE QUALITY CASTING DURING PRODUCTION.
p SPECTROMETER :- 1 NO. ( MAKER : SHIMAZDU JAPAN)
PURPOSE OF THIS IS PROPER CHEMICAL COMPOSITION CHECK TO ENSURE CORRECTMETALLURGICAL PROPERTIES.
p RESIN COATED SAND TEST EQUIPMENT : 4 NO.S ( MAKER : DIETERT U.K )
PURPOSE OF THIS IS TO ENSURE CORRECT PARAMETERS OF TWO TYPES OF RCS TO BE USED IN PRODN .
p FATIGUE TESTER :- 1 NO. ( MAKER : MTS )
PURPOSE OF THIS IS TO ENSURE THE FUNCTION , FRACTURE CHECK AFTER SUBJECTINGTHE COMPONENT TO VARIOUS VIBRATION MODES
ALDC – Process Flow Chart
n PROCESS FLOWCYLINDER HEAD CASTING
AL GBF AFTER FINALMELTING TREATING TREATMENT PRODUCT
TRIMMING M/C DOHC C/HEADKNOCK OUT M/C ( DOMESTIC,T - 4 TREATMENT EXPORT )
CORE DIE LEAK TESTINGMAKING COATING
TRANS AXLE CASE CASTING
AL HOLDING AFTER FINALMELTING FURNACE TREATMENT PRODUCT
TRIMMING D - 16SHOT BLAST T / AXLE CASE
DIE CASTINGHIGH PRESSURE
2250 TON DIECASTING M/C
CASTINGLOW PRESSURE
LOW PRESSURECASTING MACHINES
FINISH LINE
SAND BURNOUT FURNACE
HEAT TREATMENT FURNACE
GAS BUBBLING FIXTURE
ALDC
MELTING FURNACE
SAND CORE LINE
SHOT BLASTING
SAND TESTING
ALDC
X-RAY SPECTROMETER
ALDC TEST LAB
Press Shop
Press Shop with two transfer presses and one transfer line and related equipment with an annual capacity to manufacture 200,000 car bodies or equivalent.
PIM : Press Shop
Manufacturing Process Flow – Press Shop
3.1.2 MANUFACTURING PROCESS FLOW
COILBLANKING / SHEARING
700 Ton Blanking LineAUTO WAREHOUSE
2300 Ton TANDOM LINE
3500 Ton TRANSFER LINE
2400 Ton TRANSFER LINE
INSPECTION
INSPECTION
INSPECTION
STORAGE RACKS
STORAGE RACKS
STORAGE RACKS
PANEL
STORAGE
AREA
Press Shop - Introduction
1 MACHINE & EQUIPMENTp PRESS MACHINE
p AUTOMATIONALL THE SAID MACHINE ARE HIGHLY AUTOMATIC WITH THE AUTOMATION LEVEL OF 80% ~ 90 %
p FLEXIBILITYALL THE MACHINE ARE FLEXIBILE
2 TOOLINGp PRESS DIES
a. CIELO 217 No. b. MATIZ 139 No.p CHECKING FIXTURES
a. CIELO 31 No. b. MATIZ 31 No.p FLEXIBILITY : ALL TOOLING ARE SPECIALISED AND ARE NOT FLEXIBLE ( MODEL PECULIAR ONLY )
3 PRODUCTION PARTS ( BODY PARTS )p CIELO : 57 No. p MATIZ : 36 No.p Max Pnl Size : 1410(Width) x 3140(Pitch),Thickness 0.6~2mmp Max Pnl Size : 1530(Width) x 2680(Pitch),Thickness 0.6~1.2mm
4 PRODUCTION ENGG BACKGROUNDp DIE DESIGN & CHECKING FIXTURE DESIGN CAPABILITYp DIE MANUFACTURING FACILITY ( BY CAD / CAM ), MANUFACTURED SMALL DIES ( 1.5 m x 1.0 m )p DIE MODIFICATION AND ENGINEERING CHANGES IMPLEMENTATION CAPABILITY
a.
c.
3500Ton TRANFER PRESS, TOTAL 5 STAGES & 2No. SLIDES HAVING TRI AXIS MOTION
2300 Ton SINGLE ACTION TANDEM LINE , TOTAL 5No. PRESSES2400Ton TRANFER PRESS, TOTAL 5 STAGES & 2No. SLIDES HAVING TRI AXIS MOTION
700Ton SINGLE ACTION BLANKING PRESSd.
b.
Material & Equipment sourcing List Press Shop
S. No
M&E DESCRIPTION FLEXIBILITY AUTOMATION MAKER / SUPPLIER YEAR OF INSTALL
SOURCE
b} 2300 & 1000 T ons PRESSES WITH DIE CUSHION
c} MAX S.P.M : 16
a} No. OFSLIDES : 2 & No.OF STAGES : 5
b} TRI AXIS MOTION
c} MAX S.P.M : 16
a} SINGLE ACTION PRESS
b} MAX S.P.M : 80
a} TYPE : KSB - 3030 D
b} MAX. BALE SIZE : 300 x 300 X 300 ~ 350 mm
a} MODEL - 16 ES , SINGLE COLUMN
b} BED SIZE -
IMPORT
1997 IMPORT
TECHNICAL SPECIFICATION
SET OF 5No.INDIVIDUAL PRESSES WITH 2300, 1000, 1000, 500 & 500 Tons CAPACITY
a}2300Ton SINGLE ACTION TANDEM LINE
LAY-OUT MACHINE
SET OF DESTACK FEEDER , 1 LOADER AND 5 UNLOADER
MAX. SPEED 90m/min , MAX COIL WEIGHT 20Ton, WITH WASHING UNIT & TRAPAZOID SHEAR
1997 IMPORT
HITACHI ZOSEN 1997 IMPORT
2 HITACHI ZOSEN3500Ton TRANFER PRESS
1 FLEXIBLE
FLEXIBLE
~ 60 % AUTOMATION
~ 80 % AUTOMATION
5 TOKYO BOEKI
1997
1997
1997
HITACHI ZOSEN700Ton BLANKING PRESS3
SCRAP BALER4
IMPORT
IMPORT
IMPORT
~ 80 % AUTOMATION
FLEXIBLE
FLEXBILE
FLEXIBLE
DAEWOO CORPORATION
~ 80 % AUTOMATION
~ 80 % AUTOMATION
~ 80 % AUTOMATION
FLEXIBLE7 a}
6DAEWOO
CORPORATIONFLEXIBLE
AUTOMATIC EQUIPMENT FOR 2300 TON TANDEM LINE
DAEWOO CORPORATION
1997a}COIL FEED LINE
Material & Equipment sourcing List Press Shop
b} MAX. ALLOWABLE LOAD / CELL = 5 Ton
a} CAPACITY : 40 Ton , 24V DC BATTERY DRIVEN
b} USAGE : DIE TRANSFER
a} CAPACITY : 100Ton
b} HYDRAULIC PRESS
a} CAPACITY : 100Ton
b} HANGER IS HAVING ADJUSTABLE ARMS
a} MODEL : RB4N
b} 4 AXIS MOVEMENT
a} No. OF SLIDES : 2
b} No OF STAGES : 5 , TRI AXIS TRANSFER MOTION
c} MAX S.P.M : 18
IMPORT
IMPORT
1997 IMPORT
1997
IMPORT
COIL HANGER13 DAEHUNG 1997 IMPORT
HITACHI ZOSEN 1997DIE SPOTTING PRESS12 FLEXIBLE
11
TONGMYUNG
SOOSUNG
a}AUTO WAREHOUSE SYSTEM
10
2No STORAGE RACKS WITH 220 & 225 INDIVIDUAL CELLS FLEXIBLE
FLEXIBLE
~ 90% AUTOMATION
TRACK CAR
DESTACK FEEDER FOR 3500 TON TRANSFER PRESS
SCRAP CONVEYOR
8 a}
9DAEWOO
CORPORATION1997
DESTACK FEEDER WITH WASHING UNITDAEWOO
CORPORATION
a}SET OF 4No.OF LINE CONVEYOR { 1No MAIN , 1No. LIFT UP, 2No BALE & 1No SLAT CONVEYOR }
1997FLEXIBLE
FLEXIBLE
~ 80% AUTOMATION
~ 80% AUTOMATION
IMPORT
SNK 1997 IMPORT
HITACHI ZOSEN 1997
NC MILLING MACHINE
~ 80 % AUTOMATION
FLEXIBLE
16 a} DESTACK FEEDER WITH WASING UNIT
14
152400 Ton TRANSFER PRESS
AISAKU 1997 IMPORTDESTACK FEEDRE FOR 2400 ToN TRANSFER PRESS
FLEXIBLE~ 80 %
AUTOMATION
IMPORT
~ 60 % AUTOMATION
~ 60 % AUTOMATION
~ 60 % AUTOMATION
~ 80 % AUTOMATION
FLEXIBLE
FLEXIBLE
SIZE : MAX. - 1500W x 5500 LMIN. - 1500W x 4000 L
b} SPEED : 40 m/min
18 RADIAL DRILL MACHINE a} TYPE : BR 615 FLEXIBLE BATLIBOI 1997 LOCAL
19 UPRIGHT DRILL MACHINE a} MODEL : P2 / 25 / GT / 10 FLEXIBLE BATLIBOI 1997 LOCAL
20 SURFACE GRINDER a} MODEL : MK 350 x 700 SG FLEXIBLE KIRLOSKAR 1997 LOCAL
21 MILLING MACHINE a} TYPE : 8 RCU 15 FLEXIBLE BATLIBOI 1997 LOCAL
22 TOOL & CUTTER GRINDER a} MODEL : GTC 28 FLEXIBLE HMT 1997 LOCAL
23 UNIVERSAL GRINDER a} MODEL : GCU 260 x 500 FLEXIBLE PARISUDHA 1997 LOCAL
24 BEND SAW a} MODEL : 36 HT FLEXIBLE BATLIBOI 1997 LOCAL
MODEL : 36 HTWITH CONTOURING ATTACHMENT
a} MODEL : GS - 10 - 0330 - 715 ; CAPACITY - 3mm b} SPM : 65
a} MAIN HOOK : 20 Ton , AUX HOOK - 10Tonb} SPAN : 23.2 Ma} MAIN HOOK : 30 Ton , AUX HOOK - 10Tonb} SPAN : 23.2 Ma} HOOK : 5 Ton , SPAN : 8.2 M
WITH ELECTROMAGNET WITH BATTERY BACKUPa} MAIN HOOK : 40 Ton , AUX HOOK - 10Ton
b} SPAN : 23.2 M
TELESCOPIC CONVEYOR17 1997 IMPORTDAEOO
CORPORATIONa}
26 SHEARING M/c GODREJ / BOYCE
FLEXIBLE100 %
AUTOMATION
27
28 EOT CRANE ( 20 T x 10 )
PROFILE / CONTOUR CUTTER
25 BATLIBOIa} FLEXIBLE
MODEL : ENTERPRISE 500 KIRLOSKARLATHE ( 400 x 750 mm ) MACHINE
a}
1997
1997FLEXIBLE
FLEXIBLE
1997MUKUND
FLEXIBLE
FLEXIBLE
30EOT CRANE ( 5 T x 10 ) , SCRAP BALER
MUKUND 1997 LOCAL
29 EOT CRANE ( 30 T x 10 ) MUKUND 1997FLEXIBLE
FLEXIBLE31 EOT CRANE ( 40 T x 10 ) MUKUND 1997 LOCAL
1997 LOCAL
LOCAL
LOCAL
LOCAL
LOCAL
a. No. Of Stages : 8a. No. Of Stages : 4
Material & Equipment sourcing List Press Shop
Body Shop, Paint Shop & Assembly Shop
Shop Introduction – Body Shop
1 MACHINE & EQUIPMENT
PSW GUNS PROJ WELDER TR/TC HOIST HEMM'G
PRESSSTUD
WELDERSEALER PUMP
MIG WELDING
191 No. 13 No. 128 No. 11 No. 3 No. 6 No. 5 No. 14 No.197 No. 16 No. 160 No. 9 No. 3 No. 4 No. 13 No. 15 No.
p AUTOMATIONALL THE SAID EQUIPMENT ARE MANUAL EXCEPT FOR THE HEMMING PRESS WHICH IS FULLY AUTOMATIC
p FLEXIBILITYALL THE SAID MACHINE & EQUIPMENT ARE FLEXIBLE .
2 TOOLINGp WELDING JIGS
a. CIELO : 83 No. b. MATIZ : 101 No.p UNDERSHUTTLE
a. CIELO : MAIN BODY LINE b. MATIZ : UNDER BODY AND MAIN BODY LINEp CHECKING FIXTURES
a. CIELO : 24 No. b. MATIZ : 3-D CMM Machine ( With Manual Jigs )n FLEXIBILITY : ALL TOOLING ARE SPECIALISED AND ARE NOT FLEXIBLE ( MODEL PECULIAR ONLY ), EXCEPT FOR 3-D CMM
3 PRODUCTION PARTS ( BODY PARTS )
4 PRODUCTION ENGG BACKGROUNDp WELDING DESIGN & CHECKING GUAGES / FIXTURE DESIGN CAPABILITYp WELDING JIG MANUFACTURING FACILITY , MANUFACTURED WELDING JIG ( 2 m x 1.0 m )p WELDING JIG MODIFICATION AND ENGINEERING CHANGES IMPLEMENTATION CAPABILITY
p
Eqmt
CIELOMATIZ
SEPARATE WELDING LINE ARE INSTALLED FOR PRODUCING THE CIELO & MATIZ BODY SHELL. BODY IN WHITE ( B.I.W. ) LINE IS COMMON FOR BOTH THE MODELS.
Model
Pre Ass'y Under Body Main Body BIW Line Repair
Side Body Hemming Line
SubAss'y
Body Shop
Process Flow Chart – Body Shop
UNDER BODY SUB ASS'Y
MAIN BODY MAIN ASS'YHEMMING LINE
SIDE BODYSHUTTLE TRANSFER MECHANISM
SHUTTLE TRANSFER MECHANISM
U / BODY # 10 RR FLR
U / BODY # 15
U / BODY # 20
U / BODY # 30
U / BODY # 40
U / BODY # 50
U / BODY # 60
U / BODY # 70
U / BODY INSP JIG
DASH CPL # 20
DASH CTR
RAD SUPT
APRON OTR LHAPRON OTR RH
DASH SIDE LHDASH SIDE RH
FRT FLR # 20
FRT FLR # 10
C/MBR FRT FLR
M / BODY # 60
M / BODY # 50
M / BODY # 40
M / BODY # 30
M / BODY # 20
M / BODY # 10
DASH CPL # 30
DASH CPL # 10
BODY IN WHITE( B.I.W ) CHAIN
CONVEYOR
FRT DR ASS'Y
RR DR ASS'Y
E/G HOOD & T/ GATE
S / BODY # 30 ~ 40
S / BODY # 30 ~ 40
S / BODY # 10 ~ 20
S / BODY # 10 ~ 20
CTR PLR LH
FRT PLR LH
FRT FLR RH
CTR PLR RH
UNDER BODY MAIN LINE
Process Flow – Body Shop
Material & Equipment Sourcing & List Body Shop
S. No
M&E DESCRIPTION FLEXIBILITY AUTOMATION MAKER / SUPPLIER YEAR OF INSTALL
SOURCE
p SINGLE PHASE AC 440V / AC, 50 / 60 Hz
a} Power Consumption : 500 A
Cooling Condition : Controller - Natural Air
Cooling Condition : SCR - Water Cooled
c} Primary Current : 50 ~ 1500 Amps
d} Secondary Current : 2 ~ 25.5 k Amp
p STATIC CHARICTERISTICS : CONSTANT POTENTIAL
b} Open Circuit Voltage : 16 to 36 V
c} Cooling Forced Air
d} Input Supply : 415V, 3 Phase, 50 Hz
e} Inert Gas : CO2
LOCAL
1995 ( Cielo ) &
1998 { Matiz }
LOCALADVANI / MOGRA
CHOWEL MAKE { Type : OK - 350 }
1998 { Matiz }
a}
CO2 WELDING2 FLEXIBLE
CHOWEL MAKE { Type : WELCOM 200
}
CHOWEL MAKE { Type : WELCOM 200
}
JAI HIND SCIAKY { Type : PSA - 150 }
Max Weld'g Current / Load Vol. : 250 / 6.5 at 60% Duty Cycle
FLEXIBLE~ 70%
AUTOMATION
FLEXIBLE~ 40%
AUTOMATION
1998IMPORT /
LOCAL
1998LOCAL / IMPORT
1995 & 1996
( CIELO )LOCAL
TECHNICAL SPECIFICATION
Weld Control Method :Loop Control by Primary Current F/ Back
b}
Display of welding current & Self Dignosis of Troubles
e}
1TR / TC ( TRANSFORMER & CONTROLLER
Material & Equipment List – Body Shop
S. No M&E DESCRIPTION FLEXIBILITY AUTOMATION MAKER / SUPPLIER YEAR OF
INSTALL SOURCE
a} Rated Capacity : 75 KVA
b} Rated Input Voltage : 415 V , 50 Hz
c} Max O/P Short Circuit Current : 22000 A
d} Max I/P Power : 220 KVA
e} Max Electrode Force : 800kgf / cm2
a} CYLINDER SIZE : 224 dia x 150 dia x 820 stroke
b} CYLINDER POWER : For Hemm'g - 137.9 Ton
c} CYLINDER POWER : For Ram up - 46 kgf / cm2
d} Speed : 52 mm / sec ~ 24 mm / sec
e} Time Lag : 52 sec.
f} Motor : 11KW x 6P x 415V x 50 Hz
a} PUMP RAT IO - 40 : 1, OUTPUT/Cycles - 110cc
b} STROKE LENGTH : 120mm, SPRAY VOL/Min : 5.5
c} AIR INLET PR : 8 Bar
a} TYPES : " X " & "C"
TECHNICAL SPECIFICATION
SAMHEUNG & OBARA
1995 {Cielo} & 1998 {Matiz}
IMPORTFLEXIBLE
IMPORT / LOCAL
USED FOR WELDING PANEL OF VARYING THICKNESS, WITH THE APPLICATION OF HIGH PRESS & CURRENT
b}
1995 {Cielo} & 1998 {Matiz}
FLEXIBLE
5
SEALER PUMP6VR COATING ,
DONGWA , GRACO
a}STUD WELDER FLEXIBLE
IMPORT
HEMMING PRESS4
1995 {Cielo}WELDING HEAT DEVELOPED BETWEEN THE
STUD & WORKPIECE ; PRIMARY POWER : 480 V
IMPORT
1998 {Matiz}
IMPORT
IMPORT
TRW, NELSON
LOCAL
JAI HIND SCIAKY 1995
{ Cielo }LOCAL
1996 { Cielo }
1998 { Cielo }
1998 { Matiz }
CHOWEL MAKE
SAMJOO
SSW3 FLEXIBLE
100% AUTOMATION
FLEXIBLE
7 PSW & MULT I GUNS
Material and Equipment List Body Shop
S. No
M&E DESCRIPTION FLEXIBILITY AUTOMATION MAKER / SUPPLIER YEAR OF INSTALL
SOURCE
a} TYPE : MK 3004 , Art No 66, 22020.2
b} UN 35V , P = 100VA
a} CAPACITY = 500Kg ; Lift = 7Meters
b} INDUCTION MOTORS : 415 V
c} Amps : 2 Amps ( F.L.)
a} CAPACITY = 1000Kg ; Lift = 6Meters
b} INDUCTION MOTORS : 415 V
c} Amps : 3 Amps ( F.L.)
a] LIFT & CARRY MECHANISM
a] LIFT & CARRY MECHANISM
a} CHAIN PULLEY CONVEYOR
b} LENGTH : 65M
a} TYPE : DMB - 1680 , Capacity - 200 TR
b} WATER & AIR FLOW RATE - 2800 LPM & 61770 CFM
c} TEMPERATURE RANGE : 350C ~ 450C
a} CO-ORDINATE MEASURING WITH TWIN COLUMN
b} BED SIZE : 6000 mm x 3500mm
TECHNICAL SPECIFICATION
FLEXIBLE IMPORT
LOCAL
PRAJA MECHANICALS 1995 LOCAL
FLEXIBLE
NOT FLEXIBLE
NOT FLEXIBLE
COOLING TOWERS14
1995 {Cielo} & 1998 {Matiz}
15 LAYOUT MACHINE TOKYO BOEKI 1998
FLEXIBLE
13 B.I.W CONVEYOR~ 60%
AUTOMATIONFLEXIBLE
1998 IMPORT
1995 {Cielo} & 1998 {Matiz}
IMPORT
CHANGIL
12 MAIN BODY SHUTTLECHANGIL ( Cielo )
& TAEKWANG ( Matiz )b}
TO TRANSFER BODY / ASS'Y FROM ONE STN TO OTHER
10
TO TRANSFER BODY / ASS'Y FROM ONE STN TO OTHER
b}
UNDERBODY SHUTTLE
11
LOCAL / IMPORT
INDEF & DEMAG
HOIST 1 Ton INDEF
1995 {Cielo} & 1998 {Matiz}
LOCAL
HOIST 0.5 Ton9
1995 {Cielo} & 1998 {Matiz}
SCHILLING 20008
FLEXIBLE
IMPORTNo. PUNCHING M/c FLEXIBLE
Shop Introduction – Paint Shop
1 MACHINE & EQUIPMENTp PRETREATMENT & CED LINE
a. AUTOMATION LEVEL : FULLY AUTOMATIC c. MAX. SIZE OF HANGER : 2.2 mtr.(W) X 2.1 mtr.(H)b. E.D. PAINT GENERATION : GENERATION 5
p PAINT SPRAY BOOTHSa. APPLICABLE LINES : PRIMER , TOP COAT # 1 AND TOP COAT # 2 c. MAX. BOOTH GATE SIZE : 2.2 mtr.(W) X 2.3 mtr.(H)b. PAINT SPRAY SYSTEM : MANUAL d. No. OF STAGES : 7 ~ 9
p BAKING OVENSa. APPLICABLE LINES : CED , SEALER , PRIMER , TOP COAT # 1 AND TOP COAT # 2b. FIRING FUEL : LPG & DIESELc. MAX. OVEN GATE SIZE : 2.2 mtr.(W) X 2.1 mtr.(H)
p PAINT MIXING ROOMa. TOP COAT MIXING ROOM PAINT SUPPLY LINES : 12b. PRIMER PAINT MIXING ROOM PAINT SUPPLY LINES : 6c. TYPE OF PAINT MATERIAL APPLIED : SOLID , METALLIC & MICA PAINTS.
p FLEXIBILITYALL THE MACHINES IN PAINT SHOP ARE FLEXIBLE
2 PRODUCTION MODELp CIELO BODY SHELL AND MATIZ BODY SHELL ( DOMESTIC & EXPORT )
3 PRODUCTION ENGG BACKGROUNDp MAX. SIZE OF BODY SHELL THAT CAN BE PAINTED : 2 mtr.(W) X 1.5 mtr.(H) ( BASED ON MAXIMUM OVEN GATE SIZE MENTIONED ABOVE p PAINT LAB FACILITY AVAILABLE FOR TESTING VARIOUS PAINT PARAMETERS SUCH AS VISCOSITY , SOLID CONTENT ,
SPECIFIC GRAVITY , DFT , DOI , GLOSS , ADHESION ETC.p PAINT SHOP IS AIR PRESSURISED BY 04 Nos. FORCE DRAFT VENTILATION SYSTEMS TO MAINTAIN POSITIVE AIR PRESSURE
FOR PREVENTION OF DUST ENTRY.
W.B.S
# 1 UP SP. Rinse
Demasking
Sealer Bake
Top Coat Bake
Inspection
CED Stg - II CED STG - 1
# 2 UF Dip Rinse
Under Body
Primer T.Rag
DI Spr. Rinse
DI Dip Rinse
Deadner
Primer Spray
Top Coat Spr.
2nd Polishing
FLASH OFF
1st POLISH'G
Predegrease Degrease # 1 Spr. Rinse
# 4 Dip Rinse
Spr. DI Rinse
Sealing
Flash Off
T/C T.Rag
Baking Repair
# 2 Dip Rinse
# 3 Spr. Rinse
Air Blow
CED Sanding
Primer Bake
Insp. & Repair
Final Inspection
Sur. Conditioning
Phosphate
CED Bake
Masking
Inspection
Moist Sanding
P.B.S
Shop Introduction – Paint Shop
M&E Sourcing List – Paint Shop
S. No M&E DESCRIPTION FLEXIBILIT
YAUTOMATIO
N MAKER /
SUPPLIERYEAR OF INSTALL SOURCE
p PRETREAT MENT
a} BODY HANGERS ( 15 Nos. ) DWMC 1996 IMPORT / LOCAL
b} AUTO HOISTS ( 15 Nos.) DWMC 1996 IMPORT
c} LOADING LIFTER DWMC 1998 IMPORT
d} SPRAY TYPE PREDEGREASE CHAMBER HADEN JOST 1996 LOCAL
e} DIP TYPE DEGREASE CHAMBER HADEN JOST 1996 LOCAL
f} SPRAY TYPE CONDITIONING CHAMBER HADEN JOST 1996 LOCAL
g} DIP TYPE PHOSPHATING CHAMBER HADEN JOST 1996 LOCAL
p ELECTRODEPOSIT ION
a} DIP TYPE CED CHAMBER. HADEN JOST 1996 LOCAL
b} SPRAY TYPE UF # 1 CHAMBER HADEN JOST 1996 LOCAL
c} DIP TYPE UF # 2 CHAMBER HADEN JOST 1996 LOCAL
d} UNLOADING LIFTER DWMC 1998 IMPORT
e} BAKING OVEN : CONVECTION TYPE , HSD FIRED, RECIRCULATING HOT AIR.
HADEN JOST 1996 LOCAL
f} OVEN CONVEYOR : CHAIN TYPE , PITCH - 5.1 mtr
VINAR SYSTEMS 1996 LOCAL
TECHNICAL SPECIFICATION
1PRETREATMENT & ELECT RODEPOSITION LINE
FLEXIBILE~ 85%
AUTOMATION
FLEXIBLE~ 100 %
AUTOMATION
Specs :a. No. Of Stages : 17b. Overall Dimensions:
Length : 98 MeterWidth : 4.5 MeterHeight : 5.025 Meter
M&E Sourcing List– Paint Shop
S. No
M&E DESCRIPTION FLEXIBILITY AUTOMATION MAKER / SUPPLIERYEAR OF INSTALL
SOURCE
a} INSPECTION BOOTH ABB 1996 LOCAL
b} ORBITAL SANDERS 1996 LOCAL
c} EXHAUST FANS : TOTAL CAPACITY - 1200 CMM
ABB 1996 LOCAL
a}SEALER GUNS : AIRLESS DISPENSING & SEALER PUMPS
GRACO 1996 LOCAL
b}SEALER CONVEYOR : CHAIN TYPE,PITCH - 5.4 mtr
VINAR SYSTEMS 1996 LOCAL
a} TWO POST LIFTER AUTOCARE 1996 LOCAL
b} UNDERCOAT GUNS : AIRLESS DISPENSING GRACO 1996 LOCAL
c} UNDERCOAT PUMPS GRACO 1996 LOCAL
d} BOOTH ABB 1996 LOCAL
e} EXHAUST FANS : TOTAL CAPACITY - 2867 CMM
ABB 1996 LOCAL
f} OVEN CONVEYOR : CHAIN TYPE , PITCH - 5.1 mtr
VINAR SYSTEMS 1996 LOCAL
g}BAKING OVEN : CONVECTION TYPE , HSD FIRED, RECIRCULATING HOT AIR.
ABB 1996 LOCAL
TECHNICAL SPECIFICATION
2
DRY SANDING LINE
3
SEALER LINE
4
UNDERCOAT LINE
FLEXIBLE
FLEXIBLE
FLEXIBLE
Specs :a. No. Of Stages : 3b. Overall Dimensions:
14M (Ln) x 5M(Wd) x 3.2M (Ht )
a. No. Of Stages : 8b. Overall Dimensions:
43M(L) x 3M(W) x 3.15M(Ht )
Specs :a. No. Of Stages : 2b. Overall Dimensions:
Length : 16 MeterWidth : 5 MeterHeight : 3.75 Meter
M&E Sourcing LIST – Paint Shop
S. No
M&E DESCRIPTION FLEXIBILITY AUTOMATION MAKER / SUPPLIERYEAR OF INSTALL
SOURCE
a} AIR SUPPLY UNIT : AIR SUPPLY CAPACITY - 5500 CMM THERMAX 1996 LOCAL
b} SOLVENT WIPE ZONE : 1 STAGE THERMAX 1996 LOCAL
c} TACK RAG BOOTH : 1 STAGE THERMAX 1996 LOCAL
d} PAINTING BOOTH : 04 PAINTING STAGES , EXHAUST CAPACITY - 4700 CMM
THERMAX 1996 LOCAL
e} FLASH OFF ZONE : 3 STAGE THERMAX 1996 LOCAL
f} BAKING OVEN : CONVECTION TYPE , HSD FIRED, RECIRCULATING HOT AIR.
THERMAX 1996 LOCAL
g} CONVEYOR : CHAIN TYPE , PITCH - 5.4 mtr. VINAR SYSTEMS 1996 LOCAL
TECHNICAL SPECIFICATION
5
PRIMER LINE
FLEXIBLESpecs :a. No. Of Stages :9b. Overall Dimensions:
Length : 60.3 MeterWidth : 5.0 MeterHeight : 4.0 Meter
M&E List – Paint Shop
S. No M&E DESCRIPTION FLEXIBILITY AUTOMATION MAKER / SUPPLIER YEAR OF
INSTALL SOURCE
a} INSPECTION BOOTH ABB 1996 LOCAL
b} CONVEYOR : CHAIN TYPE , PITCH - 5.4 mtr. VINAR SYSTEMS 1996 LOCAL
a}AIR SUPPLY UNIT : AIR SUPPLY CAPACITY - 6200 CMM HADEN JOST 1995 LOCAL
b} TACK RAG BOOTH : 1 STAGE HADEN JOST 1995 LOCAL
c} PAINTING BOOTH : 04 PAINTING STAGES , EXHAUST CAPACITY - 5630 CMM
HADEN JOST 1995 LOCAL
d} FLASH OFF ZONE : 1 STAGE HADEN JOST 1995 LOCAL
e} BOOTH CONVEYOR : CHAIN TYPE , PITCH - 6.3 mtr. HADEN JOST 1995 LOCAL
f} BAKING OVEN : CONVECTION TYPE , LPG FIRED, RECIRCULATING HOT AIR.
HADEN JOST 1995 LOCAL
g} OVEN CONVEYOR : CHAIN TYPE , PITCH - 5.1 mtr. HADEN JOST 1995 LOCAL
a}AIR SUPPLY UNIT : AIR SUPPLY CAPACITY - 7500 CMM HADEN JOST / DWMC 1999
IMPORT / LOCAL
b} SOLVENT WIPE ZONE : 1 STAGE HADEN JOST / DWMC 1999IMPORT /
LOCAL
c} TACK RAG BOOTH : 1 STAGE HADEN JOST / DWMC 1999IMPORT /
LOCAL
d} PAINTING BOOTH : 06 PAINTING STAGES , EXHAUST CAPACITY - 7090 CMM
HADEN JOST / DWMC 1999 IMPORT / LOCAL
e} FLASH OFF ZONE : 1 STAGE HADEN JOST / DWMC 1999 IMPORT / LOCAL
f} BOOTH CONVEYOR : CHAIN TYPE , PITCH - 6.3 mtr. HADEN JOST 1995 LOCAL
g} BAKING OVEN : CONVECTION TYPE , LPG FIRED, RECIRCULATING HOT AIR. HADEN JOST / DWMC 1999 IMPORT /
LOCAL
h} OVEN CONVEYOR : CHAIN TYPE , PITCH - 5.1 mtr. HADEN JOST 1995 LOCAL
TECHNICAL SPECIFICATION
6
WET SANDING LINE
7
8
TOP COAT # 1 LINE
TOP COAT # 2 LINE
FLEXIBLE
FLEXIBLE
FLEXIBLEa. No. Of Stages : 4b. Overall Dimensions:
24.7M(L) x 5M(W) x 3.2M(Ht
Specs :a. No. Of Stages :7b. Overall Dimensions:
Length : 40 MeterWidth : 5.5 MeterHeight : 3.5 Meter
Specs :a. No. Of Stages : 9b. Overall Dimensions:
Length : 63.5 MeterWidth : 5.5 MeterHeight : 3.9 Meter
M&E List – Paint Shop
S. No
M&E DESCRIPTION FLEXIBILITY AUTOMATION MAKER / SUPPLIERYEAR OF INSTALL
SOURCE
a} CIRCULAT ION PUMP
- PUMP RAT IO : 3.5 : 1
- CONTINUOUS FLOW ( MAX ) : 65.18 LPM
- VOLUME 1 CYCLE : 37 OZ
- AIR INLET PRESSURE RANGE : 40 ~ 100 PSI
- FLUID PRESSURE ( MAX ) : 350 PSI
b} TRANSFER PUMP ( DIAPHRAGM TYPE )
- PUMP RAT IO : 1 : 1
- FLUID FLOW DELIVERY ( MAX ) : 60 LPM
- PUMP SPEED ( MAX ) : 200 CYCLE / MIN.
- AIR INLET PRESSURE RANGE : 25 ~ 100 PSI
- FLUID PRESSURE ( MAX ) : 100 PSI
c} MIXING TANK : CAPACITY - 200 LTR. DWMC 1999 IMPORT
d} SUPPLY TANK : CAPACITY - 200 LTR. DWMC 1999 IMPORT
PAINT REPAIR a} INSPECTION BOOTH TRUTEK SYSTEMS 1995 LOCAL
b} HEATING GUN BOSCH 1995 LOCAL
c} BUFFING MACHINE WADCO 1995 LOCAL
d} CERAMIC HEATER 1995 IMPORT
TECHNICAL SPECIFICATION
1999 IMPORT
1999 IMPORT
10
DWMC
DWMC
9
PAINT MIXING
FLEXIBLE
Specs :a. No. of Lines : 18(Top Coat 12 & Primer 6 )b.No.of Supply Tanks :18(Top Coat 12 & Primer 6 )c. No.of Mixing Tanks :12(Top Coat 12)d.No.of Circulation Pumps
: 12(Top Coat 12 & Primer 6 )e.No.of Transfer Pumps
: 12(Top Coat 12)
Specs :a. No. of Lines : 3b. No. of Stages : 18c. Length : 30 Meter
Width : 3 MeterHeight : 3.15 Meter
S. No
M&E DESCRIPTION FLEXIBILITY AUTOMATION MAKER /
SUPPLIERYEAR OF INSTALL
SOURCE
a} LIFTING CAPACITY : 350 Kg
b} MAX. LIFT ING HEIGHT : 1.8 m
a} SIZE : 5 m (L) X 1.04 m (W)
b} LOADING CAPACITY : 600 Kg
a} TYPE : DRAG CHAIN TYPE FLOOR CONV.
b} LENGTH : 80 m; PITCH : 5.4 m
c} NO. OF WORKING STN : 16
d} MAX. SPEED : 2.5 m/min
a] MINIMUM SILL HT. FROM FLOOR : 500 mm 1996 LOCAL
b} LIFTING CAPACITY : 600 Kg
a} TYPE : 3 RAIL TYPE POWER ONLY C/V
b} PITCH : 5.486 m, SPEED : 2.2 m/min
c} MAX. BODY HEIGHT : 1275 mm (SILL TO ROOF)
d} TOTAL LENGTH : 214 m
e} NO. OF WORKING STN. : 24
a} TYPE : CLAM SHELL TYPE
b} MAX. LOAD CARRYING CAPACITY : 1200 Kg
c} TOTAL NO. OF HANGERS : 39
SIDE LIFTER WEBB INDIA
3 TRIM LINE CONVEYOR
1995 LOCAL
GMF, INDIA
FLEXIBLE
FLEXIBLE
FLEXIBLE
LOCAL
1995 LOCAL
PBS LIFTER
6 OVER HEAD HANGER FLEXIBLE
PRAJA MECH. 1995
FLEXIBLE
TECHNICAL SPECIFICATION
AUTOTEST1
5 OVERHEAD CONVEYOR WEBB INDIA
2 TRIM DOLLY
4
FLEXIBLE~ 100 %
AUTOMATION1996 LOCAL
WEBB INDIA 1996 LOCAL
~ 60 % AUTOMATION
~ 100 % AUTOMATION
M&E List – Paint Shop
Car Production Facility
• Body Shop, Paint Shop and Final Assembly facillity
• Capacity 72,000 cars/year on a two shift basis (16 Jobs/hour)
• Used for the production of the Matiz and Cielo models
Shop Introduction – Assembly Shop
1 MACHINE & EQUIPMENTp ASSEMBLY LINE
l TRIM LINE : l CHASSIS LINE : l FINAL LINE :- No. of Hanger : 39 - Air Con Gas Charger - - Max Wt. Carrying Capacity : 1200 kg ( For Both R134a & R12 Gas )
- Max Car Dimension ( H x W ) : 1300 x 1350 - Brake Bleeding / Power Steering Fl'g M/c
p INSPECTION LINE :
p AUTOMATION : ALL THE SAID MACHINE ARE HIGHLY AUTOMATIC WITH THE AUTOMATION LEVEL OF 70% ~ 80 %p FLEXIBILITY : ALL THE MACHINE ARE FLEXIBLE AND CAPABLE OF PRODUCING EXPORT ( LHD ) & DOMESTIC MODELS.
2 TOOLINGp PNEUMATIC AND OIL PULSE TOOLING ARE USED IN CAR ASSEMBLYp FLEXIBILITY : 90 % TOOLING ARE GENERALIZED 10% TOOLING ARE SPECIALIZED
3 PRODUCTION MODELp SIMULTANEOES PRODUCTION OF MATIZ / CIELO p MAX. PRODUCTION MODEL IN EXISTING PRODUCTION LINE NUBIRA : CRUN WT - 1247 Kg ( L 4495 x H 1430 x W 1329 mm )
4 PRODUCTION ENGG BACKGROUNDp CHECKING / TESTING EQUIPMENT MANUFACTURING AND MODIFICATION p PROCESS COMMONISATION FOR EFFICIENCY IMPROVEMENT p ENGG CHANGE IMPLEMENTATION CAPABILITY
CHAIN CONVEYOR ( Length - 80 m , Max Speed - 2.5 m / min )
OVER HEAD CONVEYOR ( Length - 214 m , Max Speed - 2.2 m / min )
DOUBLE SLAT CONVEYOR ( Length - 72 m , Speed - 1.09 m / min )
Painted Car on Trim Dolly
TOE Testing M/c A.B.S Testing M/c A.L.D.L Testing M/c Shower Tester Head Light Aiming M/c Road Test
SUB ASSEMBLY
TRIM LINE # 1( FLOOR CONVEYOR : CHAIN CONVEYOR )
Transferred To Overhead Conveyor
TRIM LINE # 2( OVERHEAD CONVEYOR )
CHASSIS LINE( OVERHEAD CONVEYOR )
FINAL LINE ( DOUBLE SLAT CONVEYOR )
GUAGE INSPECTION( Functional Check )
Customer Satisfaction INSPECTION SHOWER TESTING FINAL INSPECTION &
ROAD TEST
DELIVERY TO MARKETING
I/P, Wiring Harness, HVAC, Windshield Glass, Insulations
Frt Strut, Door Trim, Carpet,
Major Ass'y
Major Ass'y
RR Axle, Fuel Tank, E/G, Tyre, Fuel Pipes
Major Ass'y
OSRVM, Air Cleaner, Tool Kit, Roof Rack
Major Ass'y
Process Flow Chart – Assembly Shop
S. No M&E DESCRIPTION FLEXIBILITY AUTOMATION MAKER / SUPPLIER YEAR OF
INSTALL SOURCE
a} LIFTING CAPACITY : 350 Kg
b} MAX. LIFTING HEIGHT : 1.8 m
a} SIZE : 5 m (L) X 1.04 m (W)
b} LOADING CAPACITY : 600 Kg
a} TYPE : DRAG CHAIN TYPE FLOOR CONV.
b} LENGTH : 80 m; PITCH : 5.4 m
c} NO. OF WORKING STN : 16
d} MAX. SPEED : 2.5 m/min
a] MINIMUM SILL HT. FROM FLOOR : 500 mm 1996 LOCAL
b} LIFTING CAPACITY : 600 Kg
a} TYPE : 3 RAIL TYPE POWER ONLY C/V
b} PITCH : 5.486 m, SPEED : 2.2 m/min
c} MAX. BODY HEIGHT : 1275 mm (SILL TO ROOF)
d} TOTAL LENGTH : 214 m
e} NO. OF WORKING STN. : 24
a} TYPE : CLAM SHELL TYPE
b} MAX. LOAD CARRYING CAPACITY : 1200 Kg
c} TOTAL NO. OF HANGERS : 39
SIDE LIFTER WEBB INDIA
3 TRIM LINE CONVEYOR
1995 LOCAL
GMF, INDIA
FLEXIBLE
FLEXIBLE
FLEXIBLE
LOCAL
1995 LOCAL
PBS LIFTER
6 OVER HEAD HANGER FLEXIBLE
PRAJA MECH. 1995
FLEXIBLE
TECHNICAL SPECIFICATION
AUTOTEST1
5 OVERHEAD CONVEYOR WEBB INDIA
2 TRIM DOLLY
4
FLEXIBLE~ 100 %
AUTOMATION 1996 LOCAL
WEBB INDIA 1996 LOCAL
~ 60 % AUTOMATION
~ 100 % AUTOMATION
M& E Sourcing List – Assembly Shop
S. No M&E DESCRIPTION FLEXIBILITY AUTOMATION MAKER / SUPPLIER YEAR OF
INSTALL SOURCE
a} LIFT ING CAPACITY : 80 Kg
b} TRAVELLING LENGTH : 5 m
a} LIFT ING CAPACITY : 150 Kg.
b} TRAVELLING LENGTH : 5 m
a} DOUBLE SLAT TYPE
b} LOAD CAPACITY : 1230 Kg X 12 Nos.
c} SLAT WIDTH : 900 mm
a} DUAL EVACUATION TYPE
b} 2 MODEL SELECTION TYPE
a} EVACUATION AND PRESSURE FILL TYPE
b} 2 MIXING RATIO TYPE
a} EVACUATION AND PRESSURE FILL TYPE
b} NO. OF MODEL TO BE SELECT : 1
a} FILLING RANGE : 0 ~ 9,999 gm
b} NO. OF MODEL TO BE SELECT : 2
a} FILLING RANGE : 0 ~ 999 gm
b} NO. OF MODEL TO BE SELECT : 5
a} RANGE, RIM DIAMETER : 13'' ~ 15''
RIM WIDTH : 4'' ~ 6''
TECHNICAL SPECIFICATION
8 ENGINE MOUNTERDAEWOO
CORPORATION1996
FLEXIBLE
IMPORT
SUNG Am, KOREA 1998 IMPORT
9 FINAL LINE CONVEYOR
7 AXLE MOUNTERDAEWOO
CORPORATION1996 IMPORT
VINAR SYSTEMS 1995
11 INSOO, KOREA 1995 IMPORTRADIATOR COOLANT FILLING M/c
LOCAL
10BRAKE FLUID FILLING M/c
14
TYRE ASSEMBLY M/C15
12
AIRCON. GAS CHARGING M/C FOR R12 GAS
13
AIRCON. GAS CHARGING M/C FOR R134a GAS
HOFFMAN, GERMANY
POWER STEERING OIL FILLING M/c
1999 LOCAL
1996
PCU, USA
PCU, USA
PASCAL INDUSTRIAL Eqmt..
IMPORT
1997 IMPORT
1996 IMPORT
FLEXIBLE
FLEXIBLE
FLEXIBLE
FLEXIBLE
FLEXIBLE
FLEXIBLE~ 60 %
AUTOMATION
~ 80 % AUTOMATION
FLEXIBLE
FLEXIBLE
~ 60 % AUTOMATION
~ 80 % AUTOMATION
~ 80 % AUTOMATION
~ 80 % AUTOMATION
~ 80 % AUTOMATION
M& E Sourcing List – Assembly Shop
M& E Sourcing List – Assembly Shop
S. No M&E DESCRIPTION FLEXIBILITY AUTOMATION MAKER / SUPPLIER YEAR OF
INSTALL SOURCE
a} MAX. OUTSIDE DIAMETER : 760 mm
b} MAX. CROSS SECTION WIDTH : 300 mm
c} RANGE, WHEEL BEAD DIA. : 12'' ~ 16''
a} APPLICATION : FRT. WHEEL TOE SETTING ONLY
b} TYPE : OPTICAL SENSOR TYPE
c} MAX. PERMISSIBLE AXLE WT. : 1500 Kg
d} MEASURING DISTANCE : 40 +/- 10 mm
e} DISTANCE BETWEEN ROLLER CTRS. : 1350 mm
f} INTERMEDIATE LIFT CAPACITY : 750 Kg
a} MEASURABLE HEIGHT : 350 mm ~ 1200 mm
c} ACCURACY : WITHIN +/- 1/4 O
a} OPERATING METHOD : ROLLER DRIVING TYPE
b} MAX. LOAD / AXLE : 1500 Kg
c} MEASURABLE EXTENT : 0 ~ 60 Km/hour
d} ROLLER CENTRE DISTANCE : 1200 mm
e} ROLLER WIDTH : 800 mm
TECHNICAL SPECIFICATION
KOREA IYASAKA
KOREA IYASAKA
TYRE BALANCING M/C IMPORT
IMPORT
MEASURABLE RANGE : LUMINOUS INTENSITY - 0 ~ 80,000 cd
b}
ITW MICROPOISE JAPAN
1996 IMPORT
1995 IMPORT19 KOREA IYASAKA(ACCELERATION TESTER, BRAKE TESTER , AND SILE SLIP TESTER)
ABS TESTER
18
16
TOE TESTER
1996
199617
HEADLIGHT AIMER FLEXIBLE
FLEXIBLE
FLEXIBLE~ 60 %
AUTOMATION
FLEXIBLE~ 80 %
AUTOMATION
~ 80 % AUTOMATION
~ 80 % AUTOMATION
S. No
M&E DESCRIPTION FLEXIBILITY AUTOMATION MAKER / SUPPLIER YEAR OF INSTALL
SOURCE
a} MAX. OUTSIDE DIAMETER : 760 mm
b} MAX. CROSS SECTION WIDTH : 300 mm
c} RANGE, WHEEL BEAD DIA. : 12'' ~ 16''
a} APPLICATION : FRT. WHEEL TOE SETTING ONLY
b} TYPE : OPTICAL SENSOR TYPE
c} MAX. PERMISSIBLE AXLE WT. : 1500 Kg
d} MEASURING DISTANCE : 40 +/- 10 mm
e} DISTANCE BETWEEN ROLLER CTRS. : 1350 mm
f} INTERMEDIATE LIFT CAPACITY : 750 Kg
a} MEASURABLE HEIGHT : 350 mm ~ 1200 mm
c} ACCURACY : WITHIN +/- 1/4 O
a} OPERATING METHOD : ROLLER DRIVING TYPE
b} MAX. LOAD / AXLE : 1500 Kg
c} MEASURABLE EXTENT : 0 ~ 60 Km/hour
d} ROLLER CENTRE DISTANCE : 1200 mm
e} ROLLER WIDTH : 800 mm
TECHNICAL SPECIFICATION
KOREA IYASAKA
KOREA IYASAKA
TYRE BALANCING M/C IMPORT
IMPORT
MEASURABLE RANGE : LUMINOUS INTENSITY - 0 ~ 80,000 cd
b}
ITW MICROPOISE JAPAN
1996 IMPORT
1995 IMPORT19 KOREA IYASAKA(ACCELERATION TESTER, BRAKE TESTER , AND SILE SLIP TESTER)
ABS TESTER
18
16
TOE TESTER
1996
199617
HEADLIGHT AIMER FLEXIBLE
FLEXIBLE
FLEXIBLE~ 60 %
AUTOMATION
FLEXIBLE~ 80 %
AUTOMATION
~ 80 % AUTOMATION
~ 80 % AUTOMATION
M& E Sourcing List – Assembly Shop
M& E Sourcing List – Assembly Shop
S. No M&E DESCRIPTION FLEXIBILITY AUTOMATION MAKER / SUPPLIER YEAR OF
INSTALL SOURCE
a} TYPE : SINGLE SLAT CONVEYOR
b} EFFECTIVE LENGTH : 43.2 m
c} WIDTH : 450 mm
d} LOAD CAPACITY : 1230 Kg X 8 Nos.
e} MATERIAL : STAINLESS STEEL
f} MAX. SPEED : 2.2 m/min
a} MAX. PERMISSIBLE HT . OF THE CAR : 1550 mm
b} LENGTH OF SPRAY ZONE : 7.4 m
c} NO. OF SPRAY NOZZLES : 210
d} PRESSURE : 1.7 Kg/Cm2
TECHNICAL SPECIFICATION
21 SHOWER BOOTHTRUTEK
SYSTEMS1995FLEXIBLE
~ 60 % AUTOMATION
LOCAL
LOCALSHOWER CONVEYOR20 FLEXIBLE VINAR SYSTEMS, 1995~ 80 %
AUTOMATION
Plastic Moulding and Paint Shop
PIM:Plastics Injection Moulding & Painting Line.
Plastic Injection Molding and Painting Line comprising Mitsubishi 3500-Ton and 1600-Ton injection molding machines. Was used for production of Matiz and Cielo bumpers and instrument panels and energy absorbers for Cielo.
1.1 MACHINE & EQUIPMENT
p INJECTION MOULDING MACHINE 3500 TON
p INJECTION MOULDING MACHINE 1600 TON
p PART HANDLING ROBOT
p MATERIAL SUPPLY SYSTEM CONSISTING OF :
a. STORAGE TANK ( 2 Nos.) b. DRY HOPPER ( 2 Nos.) c. DEHUMIDIFYING UNIT ( 1 No.)
p MOULD CHANGER FOR MOULD CHANGING BY E.O.T. CRANE ( 35 TON CAPACITY )
p AUTOMATION LEVEL : FULLY AUTOMATIC WITH COMPLETE MACHINE PROGRAMS.
p FLEXIBILITY : ALL THE MACHINES ARE FLEXIBLE
1.2 TOOLING
p CIELO MOULDS 5 Nos. p MATIZ MOULDS 3 Nos.
p CIELO CHECKING FIXTURES 5 Nos. p MATIZ CHECKING FIXTURES 3 Nos.
1.3 PRODUCTION PARTS
p CIELO : FRT. & RR. BUMPER , FRT. & RR. ENERGY ABSORBER , INSTRUMENT PANEL
p MATIZ : FRT. & RR. BUMPER , INSTRUMENT PANEL
Shop Intro – Plastic Moldings Shop
Shop Intro – Plastic Paint Shop
2.1 MACHINE & EQUIPMENT
p PAINT SPRAY BOOTHS
a. APPLICABLE LINES : PRIMER , BASE COAT AND CLEAR COAT c. PAINT SPRAY SYSTEM : MANUAL
b. TYPE OF PAINT MATERIAL APPLIED : SOLID & METALLIC 2 - K P.U. PAINT d. MAX. BOOTH GATE SIZE : 1.85 mtr.(W) X 1.44 mtr.(H)
p BAKING OVENS
a. APPLICABLE LINES : PRETREATMENT , BASE COAT c. FIRING FUEL : LPG , INFRA RED
b. MAXIMUM OVEN GATE SIZE : 1.85 mtr.(W) X 1.42 mtr.(H)
p FLEXIBILITY : ALL THE MACHINES ARE FLEXIBLE
2.2 PRODUCTION PARTS
p ALL PLASTIC PARTS OF CIELO AND MATIZ MODELS
3 PRODUCTION ENGG BACKGROUNDp INJECTION MOULDING MACHINES ARE CAPABLE OF PRODUCING ANY PLASTIC COMPONENT.
p PLASTIC MOULDING SHOP IS AIR PRESSURISED BY FORCE DRAFT VENTILATION SYSTEM TO MAINTAIN POSITIVE AIR
PRESSURE FOR PREVENTION OF DUST ENTRY.
S. No
M&E DESCRIPTION FLEXIBILITY
AUTOMATION
MAKER / SUPPLIER
YEAR OF INSTALL
SOURCE
a} CAPACITY - 4 TON
b} FRAME MATERIAL - SS41
c} BODY & CONE MATERIAL - SUS304
a} CHAMBER SIZE ( mm ) - 574 X 620
b} RPM - 20 / 10
c} POWER CONSUMPTION - 11 Kw
d} CAPACITY - 200 ~ 500 kg / hr
e} KNIFE THICKNESS - 15 mm.
a} CHAMBER SIZE ( mm ) - 250 X 420
b} RPM - 550
c} NO. OF FLYING KNIVES - 9 Nos.
d} NO. OF STATIC KNIVES - 2 Nos.
e} POWER CONSUMPTION - 15 Kw
f} CAPACITY - 300 ~ 400 kg / hr.
1 STORAGE TANK
3 CRUSHER DWMC
2 SHREDDER
~ 80% AUTOMATION
TECHNICAL SPECIFICATION
1997
1997
DWMC
IMPORT
IMPORT
IMPORT
FLEXIBLE~ 80%
AUTOMATION
FLEXIBLE
FLEXIBLE
DWMC 1997~ 80%
AUTOMATION
M&E Sourcing List Plastic Moulding Shop
S. No M&E DESCRIPTION FLEXIBILIT
YAUTOMATIO
N MAKER /
SUPPLIERYEAR OF INSTALL SOURCE
a} CAPACITY - 1 CU. MTR.
b} MATERIAL - SUS 304
a} CAPACITY - 450 kg / hr.
b} MATERIAL - SUS 304 , SS 41
c} DRYING TYPE - TWO TOWER , HUMIDITY TYPE
d} DEW POINT : - 40 deg.C.
e} RING BLOWER - PROCESS : 5.5 Kw , REGEN : 1.9 Kw
f} REGENERATION HEATER
g} COOLING CHAMBER
h} FILTER
a} MATERIAL - SS41
b} DUST COLLECTION TYPE - AUTO AIR PULSE
c} DUST TANK - 50 L
d} FILTER - CARTRIDGE
a} COMPRESSOR - 30 Kw
b} COOLING CAPACITY - 104000 KCAL / HR
c} CHILLED WATER TEMP. RANGE - 10 ~ 15 deg.C.
d} COOLING PUMP OUTPUT - 2 kg / sq.cm. X 2.2 Kw
e} CHILLED WATER FLOW RATE - 466 L.P.M.
TECHNICAL SPECIFICATION
DEHUMIDIFYING DRYER UNIT
5 DWMC 1997 IMPORTFLEXIBLE
6 BAG FILTER 1997
~ 80% AUTOMATION
1997
FLEXIBLE DWMC
IMPORT7 CHILLER 40 H.P. DWMCFLEXIBLE
4 DRY HOPPER DWMC 1997 IMPORT~ 80% AUTOMATIONFLEXIBLE
IMPORT
~ 80% AUTOMATION
~ 80% AUTOMATION
M&E Sourcing List Plastic Moulding Shop
S. No M&E DESCRIPTION FLEXIBILIT
YAUTOMATIO
N MAKER /
SUPPLIERYEAR OF INSTALL SOURCE
a} COMPRESSOR - 22 Kw X 2
b} COOLING CAPACITY - 156000 KCAL / HR
c} CHILLED WATER TEMP. RANGE - 10 ~ 15 deg.C.
d} COOLING PUMP OUTPUT - 2 kg / sq.cm. X 2.2 Kw
e} CHILLED WATER FLOW RATE - 670 L.P.M.
a} ELECTRIC HEATER - 50 Kw
b} HEAT ING CAPACITY - 43000 KCAL / HR
c} CHILLED WATER TEMP. RANGE - 70 deg.C.
d} WATER TANK VOL. - 600W X 500D X 600H
a} ELECTRIC HEATER - 50 Kw
b} HEAT ING CAPACITY - 43000 KCAL / HR
c} CHILLED WATER TEMP. RANGE - 70 deg.C.
d} PUMP OUTPUT - 3.75 Kw
e} WATER TANK VOL. - 600W X 500D X 600H
a} MOULD CLOSE LOW SPEED - 9 ~ 10 sec / 300 mm
b} MOULD CLOSE HIGH SPEED - UNDER 1.64 sec. / 1000 mm.
c} MOULD OPEN LOW SPEED - 9 ~ 10 sec / 300 mm
d} MOULD OPEN HIGH SPEED - UNDER 1.64 sec. / 1000 mm.
TECHNICAL SPECIFICATION
CHILLER 60 H.P.~ 80%
AUTOMATION
~ 80% AUTOMATION
~ 80% AUTOMATION
IMPORT199711INJECTION MACHINE 1600 TON
FLEXIBLE~ 100%
AUTOMATION
8 DWMC
10 PRE HEATING UNIT DWMC 1997FLEXIBLE
9 MTCU 50Kw DWMCFLEXIBLE
8
1997
CHILLER 60 H.P. FLEXIBLE~ 80%
AUTOMATION
FLEXIBLE 1997
DWMC
1997 IMPORT
IMPORT
DWMC
IMPORT
IMPORT
M&E Sourcing List Plastic Moulding Shop
S. No M&E DESCRIPTION FLEXIBILIT
YAUTOMATIO
N MAKER /
SUPPLIERYEAR OF INSTALL SOURCE
a} MOULD CLOSE LOW SPEED - 9 ~ 10 sec / 300 mm
b}MOULD CLOSE HIGH SPEED - UNDER 2.34 sec. / 1000 mm.
c} MOULD OPEN LOW SPEED - 9 ~ 10 sec / 300 mm
d}MOULD OPEN HIGH SPEED - UNDER 1.64 sec. / 1000 mm.
e}SCREW BACK PRESSURE - MAX. GAUGE PRESSURE : 32 kg / sq.cm. , MIN. GAUGE PRESSURE : 5 kg / sq.cm.
f} NO. OF SCREW REVOLUTIONS - 98 RPM
TECHNICAL SPECIFICATION
IMPORTFLEXIBLE~ 100%
AUTOMATION199712
INJECTION MACHINE 3500 TON
DWMC
M&E Sourcing List Plastic Moulding Shop
Parts Storage
SURFACE INPECTION( Finished Component Quality
Check )
TOP COAT BAKE FLASH OFF Clear Coat -
II
I.P.A Wipe Tack Rag MPR Primer
Clear Coat -1
Flash Off
Flash Off
Base Coat -1
Base Coat -II
Painted PartsStorage
1st
POLISHING2nd
POLISHINGBaking Repair
Final Inspection
Quality O.K.
Quali
tyNo
t O.K
.
Process Flow Chart – Plastic Paint Shop
R & DTesting Facility
PIM : Technical Centre
• Technical Centre with all test equipment, including Chassis Dyno, Engine Dyno, Metrology and Component Test facilities.
S.NO NAME OF MACHINE /TESTING EQUIPMENT QTY MAKER'S NAME
1 METALLURGICAL MICROSCOPE WITH 1 OLYMPUS
EXPOSURE (PMG3 ) CONTROL UNIT
2 STEREO SCOPE WITH FIBRE OPTIC ILLUMINATOR 1 OLYMPUS
3 METALLURGICAL MICROSCOPE WITH EPHIP 1 NIKON
4 COLOUR DIFFERENCE METER WITH H.D. 1 HUNTER LAB
5 ELECO METER 1 GANON
6 ELECO METER PROBE MODULE 2 ELECTRO METER INSTRUMENT
7 PLASTIC TESTER STAND (15466) 1 BLUCSTEEL
8 C.S.ANALYSER CS-400 WITH PRINTER MACHINE 3201 1 LECO
9 MODULAR CHILL CAST IRON HF-400-A 1 HILGER
10 SPECTRO METER WITH BLUEBIRD SLAB 1 HILGER
11 UTM (1TON) WITH EXTENSOMETER 2 LLOYD/SHIMADZU
12 VICKER HD TESTER WITH VOLTAGE METER 2 LECO
13 ROCKWELL HD TESTER 2 SAROJ
14 MICROVICKERS HD TESTER WITH MONITOR 2 SHIMADZU
15 PROFILE PROJECTOR 10X20X50 WITH SCREEN (NIKON) 1 NIKON
16 BRINELL HD TESTER 1 SAROJ
Metal Chemical Lab – List of Equipment
S.NO NAME OF MACHINE /TESTING EQUIPMENT QTY MAKER'S NAME
MATERIAL DIMENSION
17 ROTARY TYPE ABRATION TESTER 1 TOYOSEIKI
18 VISCO METER (KINETIC VISCOSITY BATH) 1 BROOKEFILD
19 VACUUM CLEANING M/C 1 TOSHIBA
20 PRECISION BALANCE 1 AFCOSET
21 AUTO DENSTIMETER 1 TOYOSEIKI
22 DIGITAL GLOSS METER WITH ACCESS 1 TOYOSEIKI
23 VERNIER CALIPERS 100+60+30 3 MITUTOYO
24 POLISHER CUM GRINDER 220V SPEED 1 BUEHLER
25 DRYER 1 INSREF
26 MOUNTING PRESS 1 LECO
27 DISTILLATION APPARATUS 1 IN HOUSE
28 GRINDER 1 STAGE 1 METATECH
29 OVEN 250o C 2 NSW
30 ULTRASONIC CLEANER WITH RAPID TEST 1 BEUHLER
31 FLASH POINT TESTER 1 AIM-SB4
32 MELTING POINT TESTER WITH VARIABLE HI 1 SANYO
Metal Chemical Lab – List of Equipments
S.NO NAME OF MACHINE /TESTING EQUIPMENT QTY MAKER'S NAME
32 MELTING POINT TESTER WITH VARIABLE HI 1 SANYO
33 TRIM LARGE SPILL PAN 1 STRUERS
34 V BLOCK MAGNETIC 1 OMEGA
35 HEIGHT GAUGE 600M (3 NOS.) 450 M (1 NO) 4 MITUTOYO
36 ANGLE PLATE 1 MADRAS GAUGE
37 V BLOCK (SLOTTED) 2 MITUTOYO
38 MAGNETIC BLOCK 1 ARMATECH
39 HOT & COLD CHAMBER 1 KASCO
40 CLIMATE TEST CHAMBER 3 WEISSTECH
41 HOT PLATE 1 NARANG
42 SALT MIST CHAMBER 2 SELLEX
43 SALT SPRAY FOG TESTER 2 HITECHS
44 ELECTRIC BOX FURNACE 1200 o C 1 UNDBERG
45 MUFFLE FURANCE 1700oC 1 UNDBERG
46 WEATHER -O-METER 2 ATLAS
47 OZONE AGING TESTER 1 SUGA
48 OVEN DS 50, DS-40 2 DAESUNG
49 PH METER PORTABLE 1 ELINCO
50 WEIGHING MACHINE 1 INHOUSE
51 OSCILOSCOPE 1 PHILIPS
52 FLAMMBILITY TESTER 1 TOYOSEIKI
53 STANLAY TOOL BOX 1 STANLEY
54 OIL BATH 1 SCI INSTRUMENT
55 AIR COMPRESSOR 1 INDIAN
56 QUV WEATHER-O-METER 1 Q-PANEL LAB
Metal Chemical Lab – List of Equipments
Vehicle Test Lab – List of Equipment
S.NO NAME OF MACHINE /TESTING EQUIPMENT QTY MAKER'S NAME
1 2 POST LIFTER 2500 TON 4 ELGI
2 SPARK PLUG TESTER 1 ELGI
3 BATTERY CHARGER 1 RACSON
4 HEAD LAMP TESTER 1 PRECISION
5 GRINDER & POLISHER WITH VICE & PULLER 1 MOTORISED
6 WHEEL BALANCER 1 PRECISION
7 WHEEL ALLIGNMENT TESTER (JOHN BEAM) 1 JOHN BEAM
8 E/G TUNE TESTER MHC 218 1 HERMANN
9 NON CONTACT SPEEDO METER / RPM METER 1 DATRON
10 GAS CHARGER ( FREON) 1 ROBINAIR
11 WEIGHING SCALE ELECTRONICS 1 ATCO
12 OVERHEAD CRANE 1 TON 1 BATLIBOI
13 AUTOMOTIVE EMISSION GAS ANALYSER , 1 HORIBA
IDLE GAS ANALYSER
14 FUEL FLOW METER 1 DATRON
15 DATRON LAMDA SENSOR (DLS) 1 DATRON
16 FUEL PIPE (DATRON EQUIPMENT) 1 DATRON
17 SCANNER -II 1 DAEWOO
18 EURO CLEAN XLS VACUUM CLEANER 1 EUREKA FORBE
19 PUSH PULL GAUGE 1 IMADA
20 TIMING LIGHT 1
Noise Lab – List of EquipmentS.NO NAME OF MACHINE /TESTING EQUIPMENT QTY MAKER'S NAME
1 SHOCK ABSORBER PERFORMANCE TEST MACHINE KEYONG DOWITH HOT & ENVIRONMENT CHAMBERS 1
2 OIL SEAL DURABILITY TEST MACHINE 1 KEYONG DO
3 TRANSMISSION GASKET MACHINE 1 1 KEYONG DO
4 TRANSMISSION SYNCHRO RING TESTER 2 KEYONG DO
5 SPRING DUR TEST RIG 1 IN HOUSE
6 RR AXLE ROLL TEST RIG 1 GM FABRICATORS
7 HYDRAULIC FATIGUE TEST MACHINE- 100 KN WITH 1 KEYONG DODYNAMIC SERVO
8 HYDRAULIC FATIGUE TEST MACHINE-25KN WITH 1 KEYONG DODYNAMIC SERVO
9 FLY WHEEL & FAN BURST TEST MACHINE 1 KEYONG DOBYK
10 WATER PUMP DURABILITY TEST MACHINE 1 KEYONG DO
11 SHOCK ABSORBER DURABILITY TEST M/C 1 KEYONG DO
12 ALTERNATOR PERFORMANCE TESTER 1 SAMHAN
13 ALTERNATOR DURA TESTER 1 SAMHAN
14 STARTER TEST BENCH 1 SEMCO
15 HARNESS TESTER 1 IN HOUSE
16 CHARPYS IMPACT TESTER 1 SHIMDZU
General Lab – List of Equipment
S.NO NAME OF MACHINE /TESTING EQUIPMENT QTY SPEC/USE MAKER'S NAME
1 HIGH VOLTAGE TESTER 1 HIGH VOLTAGE TEST KWANG MYONG
2 TEMPERATURE SENSOR TESTER 1 HIGH & LOW TEMP. CONTROL SENSOR
KWANG MYONG
3 OIL PRESSURE SWITCH TESTER 1 TO CHECK THE OIL PRESSURE SWITCH
KWANG MYONG
4 HIGH RATE DISCHARGE TESTER 1 HIGH RATE DISCHARGE TESTER DIGATRON
5 BATTERY TESTER 1 CHARGING & DISCHARGE TEST DIGATRON
6 DECADE RESSISTANCE BOX M/C 5750,5751
2 YAISWSHIKHA
7 GALVANOMETER 2 YOKOGAWA
8 INSULATION TESTER 4 RESISTANCE TESTER KIKUKSI
9 FREQUENCY COUNTER 1 HP
10 LCR METER 1 HP
11 OSCILLOSCOPE 1 TEKTRONICS
12 FRT ANALYSER WITH GRAPHIC PLOTTER 1 BRUEL & JAER
13 A/C SWITCH RIG & CHINA BELL RIG 1 IN HOUSE
SUPPORT FACILITIES
Utilities ,Power Plant
DIE MACHININGn MAJOR WORKSCOPE :
a. PRESS DIE MANUFACTURING FOR NEW MODELSb. PRESS DIE MODIFICATION FOR NEW PRODUCT AND PDS CHANGEc. SUPPORT TO DIE MAINTENANCE , PRODUCTION & ENGG SERVICES FOR TOOLING MANUFACTURING
n MAJOR ACHIEVEMENT :FACILITY CREATION FOR IN-HOUSE PRESS DIE MANUFACTURING. FOLLOWING ARE THE PRESS DIE MANUFACTURED :p MODEL : CIELO
a. DIE MODIFICATION FOR SUPPLY CHANGE CONDITIONp MODEL : MATIZ
a. PANEL REAR SKIRT b. C/MBR DASH CENTREc. C/MBR RADIATOR LOWERd. DIE MODIFICATION FOR COMMON PRODUCTION FOR MATIZ DOMESTIC & EXPORT.
n MAJOR M&E :MAJOR M&E LIST AS PER ATTACHMENT # 4.1a
4.1
Support Facility
PIM : Utilities
• 7000 Cfm Compressed Air Capacity• Hot water Generators• Effluent Treatment Plant• Waste Incinerator• LPG Tanks• HSD Tanks• HFO Tanks• Electric cabling• Pipelines• Roads• Secured Perimeter
Looking for Business Relationships to create Wealth
Thank You