VASI Final Rep

8/6/2019 VASI Final Rep

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IN PLANT TRAINING REPORT

By Rahul Jayasurya & A.Sriram Page 1

INPLANT TRAINING

REPORT AT VISTEON

AUTOMOTIVE SYSTEMS

INDIA PVT LTD.

RAHUL JAYASURYA

A.SRIRAM

DEPT. OF MECHATRONICS

SRM UNIVERSITY

CHENNAI.


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COMPANY PROFILE

Established in March 1997, VISTEON AUTOMOTIVE SYSTEMS INDIA PVT

LTD [VASI], has established itself as a key member in the Indian Automotive

component market in a short span of 5 years.

Apart from VASI, Visteon has 2 more manufacturing units in India.

*VISTEON POWER TRAIN CONTROL SYSTEM INDIA [VPCSI]

*CLIMATE SYSTEMS INDIA

The products manufactured in these plants are given below,

*VASI Instrument Clusters, Plastic components and cockpit assemblies.

*VPCSI Starter motors, Alternators

*CSI Radiators

Apart from being a primary supplier to FORD INDIA, Visteon has also emerged asa key supplier to to major domestic and international OEMs in India like Maruti

Udyog, Toyota etc.

The company has developed a reputation for quality and has won several awards

for defect free products from its customers.

Visteon focuses on developing new supplier relationships, as well as recognizing

those relationships that have made consistently high quality contributions to its

operations. The company seeks to inculcate in its suppliers, its core principles of

safety, quality, and delivery.

Visteons growth in India is due to several factors like, Global presence and

Customer base, superior processors and product quality, locational advantages.

Visteon plans to grow in line with the growth plans of its OEM customers and has

plans to enhance its existing product offerings .


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INTRODUCTION:

In this plant we are going to see about the process involved in the manufacturing

and the assembling of the interior car parts like instrument panel, gear box console,

glove box unit etc. In all the parts the first step is manufacturing then comes the

painting of the manufactured parts and then the assembly of the parts to make it a

complete unit. Now lets see about them in detail.

Manufacturing Process:

The Visteon Automation Systems India (VASI) uses various injection molding

CNC machines for manufacturing the plastics parts that are used in the interiors of

the car. Also the robots are used for handling the finished parts. The various

injection molding machines are differentiated based on the operating weights. The

machines are available with the operating weights like 8000t for gearbox console,

3000t for door trim, 650t for glove box cover and 2500t for the instrument panel.

Also smaller parts like pin shutter, louver link, link valve, spacer valve etc are

manufactured with the help of a 120t injection molding machine. The machine

usually produces more number of components which are smaller in size at the

single cycle rather than producing only single part at a cycle like in the other cases.

Each interior part is manufactured in CNC machines based on their type and

weight. The moulds in the machines are also replaced based on the type of variants

that has to be manufactured. The material that is used for the manufacturing

process is Polypropylene. It is used in the form of small granules. Now lets us see

the manufacturing process of the interior parts. The manufacturing of the interiorplastic parts by a CNC machine involves six stages. They are

Mould Close:

In this stage, the moulds are closed. At this time, the polypropylene granules are

made to enter the hopper. In this hopper, the granules are melted. The left side of

the mould is called core and the right side of the mould is called cavity. This mould

can be replaced based on the required structure. The mould when closed the molten


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granules are made to enter the empty cavity between left and the right side parts of

the mould at a high pressure.

Tonnage:

After the mould is closed, since the molten material enters at a higher pressure, it

tends to make the moulds to open. For this, an extra force from the other is

provided and this is called as the tonnage. It helps in avoiding the opening of the

mould and thereby providing an effective injection of the material.

Material Injection:

After providing the tonnage force, the material is injected into the mould cavity

thereby causing the production of the part with the required shape.

Cooling:

In this stage the molten material which is injected into the mould cavity is made to

cool. After the cooling process, the material gets toughened. The cooling time is

usually ten seconds.

Mould Open:

After the process of cooling, the moulds are opened. Once it is opened the material

that has attained the required shape is seen fixed onto one of the mould side.

Part Ejection:

Now when the mould is opened, the robot which has got six degrees of freedom is

used to take the finished material out of the mould. It uses the vaccum gripper for

holding the finished part. This robot is programmed with the help of a teach

pendent system.

This cycle of operation is continued for the manufacture of the parts continuously.

The major plastic parts used in the interior of a car which are manufactured using

these machines are gear box console, door trim, glove box cover, instrumental

panel and the heater gauge. The interior parts that are manufactured in this plant

are used in cars like Ford Figo, Hyundai Verna Fluidic, Hyundai i20, Hyundai i10


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etc. The average cycle time for each of the components to be produced from the

CNC machine is fifty seconds.

Post Molding:

After the plastic part is manufactured it is checked for presence of defects if any by

visual means. Also the runners are cut from the final parts. After that the parts are

placed on the arrangement meant for checking the dimensions like depth, gaps etc.

This process of checking the dimensions of the parts which are produced is called

the gauge inspection. Usually this gauge inspection is done for the instrument

panel dimension checks.

After this the inspection and the quality check of the parts is done, the parts are

arranged in the carriage. These carriages are now moved on to the paint shop

where the required painting operation is carried out based on the color requirement

as prescribed by the customer. So let us now move on to the next section which is

the paint shop.

PAINT SHOP

First let us look at some of the basic terms that are associated with paints.

Paint is a homogenous mixture of Binders, Pigments, Additives and Solvents.

Purpose of Painting:

y High durability and Lifey Corrosion protectiony Good appearance and Aestheticsy Improve quality and Hide defects

Components of Paints:

Pigments: They are solid materials grounded and added mainly for giving the

required color. It also gives anti corrosive and rust inhibiting properties.

Binders: They are responsible for holding the pigments and additives and for

forming a continuous film. It gives them properties like Elasticity, Strength,

Hardness, Abrasion and Adhesion.


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Solvents: They are mainly added for ease of application. It has got no roles in the

property of the paint film. Normally, a mixture of paint is used to get the required

amount of evaporation rate, dissolving powder etc.

Additives: They are substances that are added in small quantities


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These steps are involved in the painting of the interior parts. Let us see about them

in detail.

Deribb: In deribb process the oil and the grease particles are removed from the

manufactured part. Also the extra material obtained is also removed in this stage.

This is done so that the paints that are to be applied are effective on the surface

which becomes smooth and compatible for paints.

Wipe/Air blow: In this process, surface of the part after undergoing the deribb

process is completely dried by wiping with a clean and dry cloth and as well as

exposing it to a air blow. As a result of this, the surface of the part gets dried

completely.

Basecoat: In this stage, the primer coating is applied on to the surface of the part.

This helps the actual paint to exist effectively on to the surface of the part. In other

words it acts as a medium on the surface on which the actual paint can be

effectively coated.

Flash Off: In this stage the primer coating is evaporated so as to make the primer

thin. The time for which the part is exposed for evaporation is proportional to the

DeribbWipe/Air

blowBasecoat

Flash Off Clear CoatClear

Flash Off

CuringInspection


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thickness of the primer coating present on the surface. More the explosion more

thinly becomes the primer coat.

Clear Coat: In this stage the final paint that has to be coated is applied on to the

surface. The method of application used is the Air assisted spray painting method.

The parts are sent into the paint booth in carriages. The worker sprays the paints

evenly on to the surface manually and due to the air which is blowing from the top,

the paint gets dried.

Clear Flash Off: Now the painted part is made to undergo flash off process once

again. But this time the thickness of the final paint coat is reduced by evaporating

the paint from the surface of the parts.

Curing: The painted part is now made to enter into an oven where the heating of

the part is done. This is done for the purpose of drying. The temperature of the

oven for drying the paint in the material is 85o

for 27 minutes. As a result of this

process the paint which is applied on to the surface is effectively dried.

Inspection: Here the visual inspection is carried out. The gloss and the color arechecked manually according o the requirements.

Thus after the painting process the parts are moved on to the assembly division

where the sub components are assembled on to the major parts.

Assembly Section:

The assembly section involves five sections. They are side and center vent

assembly, glove box assembly, door trim assembly, instrument panel assembly,

and the speedometer console assembly. Each assembly line gets the major partsthat are manufactured and painted from the paint shop. They also receive the

smaller parts from the 120t molding machine directly. Now lets see about these

five different assembly lines and also the processes involved in them.

Side and Center Vent Assembly:

The process flow for the side and the center vent assembly is shown below.


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The smaller parts for the assembly of the side and the center vent are obtained from the 120t machine.

The assembly line is subdivided into two. One is for assembling the side vents and the other is forassembling the LH and RH of the center vents. In the side vent assembly, the parts like housing, shutter,

louver A&B, link valve and the link spacer are assembled with the help of a pneumatic machines and

placing them and at approximate places and applying the locks and the casing is attached over the

housing part. After that the seal tape is fixed between the housing and the casing so as to close the gap

between them and prevent the unwanted noise due to vibration. After that the barcode sticker is

stricken and using the gauge dimensioning the dimensions is checked. The foam is now sticked at the

required places. Finally the quality of the vent is checked.

The center vent assembly involves the following stage of processes for LH and RH separately.

y Seal shutter assemblyy Seal shutter and Shutter control assembly with casey Case and housing assemblyy Link & louver assembly with housingy Knob assembly with housing.

After these stages the inspection of the vent parts are done manually by visual means. After the

inspection of the vents they are placed in the trays and sent to the packing area.

ReceivingGranules

Moulding

VentAssembly

EffortChecking

GaugeInspection

VisualInspection

Packing

ReceivingChild Parts

Inspection Stages


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Glove Box Assembly:

The process flow diagram involved in this section is shown below.

The various steps involved in the glove box assembly are discussed in this section. First the LH and the

RH locks are fitted on to the center rubbed springs and this arrangement is fitted on to the inner part of

the glove box. After this the locks are checked by means of a pneumatic machine. This helps in giving a

satisfaction that the inner locks are installed properly. At the same time the locks are fitted on to the

glove box cover with the help of a pneumatic machine. This is done by keeping the glove box cover

which has been obtained as a major part from molding and the lock is fitted to the moving part of the

machine. By pressing the button keeping the cover at exact place the lock is fitted on to the cover. At

last the inner part of the glove box and the cover of the glove box are welded together with the help of

the Ultrasonic Vibration Welding Machine.

Speedometer Console Assembly:

The colored outer parts are fitted on to the speedometer box at the required places that are provided.

Now the fiber glass is placed on to the outer part of the console. It is positioned at the same way into

the ultrasonic vibration welding machine and thereby joining the glass on to the console. After this the

clamps for fitting the console are placed and fitted by means of heat stamping.

Door Trim Assembly:

The process flow for the door trim assembly is shown below.

Lock AssemblyInner part andLock assembly

Bumpstop assyand Pokayoke

checking

UltrasonicVibrationWelding

Molding

Door

Welding

Weather

Flaming

Door

Kimikomi

Fabric

Assembly

Child Parts

Glue Spray

Fabric

Pokayoke Visual

Inspection


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A six degree of freedom type robot is involved in the welding of the weather strip

on to the door trim that is manufactured by the molding machine. The type of

welding is electric welding. The robot is programmed to make the welding at

particular spots. After this the place where we need to place the fabric cloth in the

door trim is made to expose under flame. This heating process helps the effective

pasting of the fabric cloth on to the door trim. After this the glue is applied on to

the fabric cloth and then the fabric cloth is fixed on to the door trim by using the

kimikomi machine, which performs this function by the pressing action. After this

the door trim is fitted with child parts like the inner door handle and the other

plugs. After this the paper tray at the bottom of the door trim is welded on to the

main structure. Now the inspection is done with the help of pokayoke process. In

this the door trim is made to enter the arrangement which is provided with the

sensors and the cameras for finding whether all the parts are present in the

assembly. Even if a single part is missing then it will not generate the success

barcode for sticking on to the door trim.

Instrument Panel Assembly:

The process flow diagram for the IP assembly is shown below.

The instrument panel is produced from the molding machine. After that it is sent to

the paint shop for the painting operation. There are two types of IP they are PAB

mode and non PAB mode. In PAB mode the airbag is present. But in non PAB

mode the air bags are not present. For PAB mode of IP the part is made to undergo

Receiving

Granules

Molding Painting Nozzle

Welding

Pokayoke

Inspection

Duct

Welding

Hole

punching

Clip

Assembly

Chute

Welding

Final

Inspection

Dispatch Fabric

Welding

Milling

and


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B R h l J & A S i P 12

milling. It helps in the opening of airbag in a short interval of time. After milling

the scoring operation is done for checking whether the milling is done exactly to

the required specifications. The milling machine used is GEISS and the scoring

machine is MOBIS. After this the nozzle welding is done on the IP. Now the clips

for fixing various instruments are fitted. After that chute welding is done. In this

the upper cap for closing the airbag section is positioned and welded by ultrasound

vibration welding. After this the duct which has got the holes and ways for

allowing the air flow is welded to the lower part of the instrument panel. Now all

the tabs and the parts present in the IP are inspected by the pokayoke method

having the sensors and cameras for the sensing purpose and generate the barcode.

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