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





26.32

29.82

43.86

44.44

3500 Ton TANDEM LINE1

2

PRODUCT NAMELINE NAME

CIELO 57

36MATIZ


% 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




3

3 TOTAL

40.00

50.008



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


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


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


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


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"


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


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


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


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


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


g}BAKING OVEN : CONVECTION TYPE , HSD FIRED, RECIRCULATING HOT AIR.

ABB 1996 LOCAL


2

DRY SANDING LINE

3

SEALER LINE

4

UNDERCOAT LINE

FLEXIBLE

FLEXIBLE

FLEXIBLE


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 )


Length : 16 MeterWidth : 5 MeterHeight : 3.75 Meter

M&E Sourcing LIST – Paint Shop

S. No


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


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


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


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.


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


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


Length : 63.5 MeterWidth : 5.5 MeterHeight : 3.9 Meter


S. No


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


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


AUTOTEST1

5 OVERHEAD CONVEYOR WEBB INDIA

2 TRIM DOLLY

4

FLEXIBLE~ 100 %

AUTOMATION1996 LOCAL

WEBB INDIA 1996 LOCAL

~ 60 % AUTOMATION

~ 100 % AUTOMATION


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


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


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


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


a} FILLING RANGE : 0 ~ 999 gm


a} RANGE, RIM DIAMETER : 13'' ~ 15''

RIM WIDTH : 4'' ~ 6''


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




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


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


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


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




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


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


1997

1997

DWMC

IMPORT

IMPORT

IMPORT

FLEXIBLE~ 80%

AUTOMATION

FLEXIBLE

FLEXIBLE

DWMC 1997~ 80%

AUTOMATION

M&E Sourcing List Plastic Moulding Shop


YAUTOMATIO

N MAKER /


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.


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



YAUTOMATIO

N MAKER /


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.


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



YAUTOMATIO

N MAKER /


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


IMPORTFLEXIBLE~ 100%

AUTOMATION199712

INJECTION MACHINE 3500 TON

DWMC


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


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


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


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

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