BODY SHOP

The process of an automotive body assembly is divided in to floor, side,

Body Build, Moving and Body Complete. The major process of an
automotive body is electric resistant welding. When electric resistant
welding is not applicable C02 Arc Welding and MIG Brazing are performed.
Moving parts such as Door, Hood, T/Lid, and Fender are attached to the
automotive body from Build Line. Several kinds of sealants are put on an
automotive body for the prevention of noise, rust and water leakage.
Drive Check and Torque check are performed for good quality of an
automotive body.
Body Drawings:
Car Line:
Putting an automobile of three dimensions into coordinates of two
dimensions.
H- Coordinates:
It indicates the cars height and its starting point is the centre of front wheel.
T- Coordinates:
It indicates a cars length and its starting point is the centre of front wheel.
L- Coordinates:
It indicates a cars width and its starting point is the centre line.
Steel sheet:
Steel Sheet used should have the following factors,
1. Body Strength
2. Plasticity
3. Paintability
4. Weldability.
5. Body Weight.
Kinds of steel sheet.
1. Cold rolled steel sheet.
(1) SPEC- Steel plate cold commercial.
(2) SPCD-Steel plate cold deep drawing.
(3) SPCE- Steel plate cold extra.
(4) SPCEN- Steel plate cold extra Non-Ageing.

2. Coated steel Sheet

A steel sheet that has been alloyed or coated Metallic film to improve
corrosion resistant, heat resistant and water resistance.
3. High Strength Steel.
BODY QC
B/C Line -2
In B/C line -2 the following activities are carried out.
1. Spec Inspection.
2. Initial Inspection.
3. Gap & Flush.
4. Final Inspection.
5. Customer Satisfaction Inspection Line.
Initial Inspection:
This is an inspection done on complete Welded body after assembling
moving parts. In Initial Inspection, Interior, Exterior, LH, RH, Front and
RR of the Body are inspected for the following,
1. Appearance.
2. Dents.
3. Damage.
4. Bolt Miss, and Proper Tightening.
5. Sealer Miss, Proper Location and Quantity.
6. Spot Weld Miss.
7. CO2 Weld Miss.
8. Brazing Uniformity.
9. Antipad in MXI and Sealer in MCI.
10. Sealer in Beam Bar.
11. VIN No.
12. Model.
13. Engine.

The defects are marked in particular area and rework is performed

immediately. Brazed area is rubbed with oil stone, while rubbing if there is
no contact point on brazing part, it is considered as dent and immediately
rework is performed on particular area. This is done to avoid uneven flow
during painting. If there is cut mark or uneven brazing, Soldering is done in
Brazed area and after that Grinding and sandering is done to make it
smooth.
Gap and Flush.
In Gap and Flush, gaps and flushes between the adjacent parts are checked.
Generally Flush will be .5-1.0 mm from FDR-FR DR, FR DR-RR DR,
RR DR-S/OTR.The reason behind this is, during drive the air runs past the
fender and does not enter through the door. Otherwise the air enters through
the door and gives air noise. Magnet is fixed between the areas where the
flush is to be checked. Flush gauge and by feeling flush is checked. Bush is
placed in the front area and the flush is checked between Hood and Fender.
Gap is checked by using Taper gauge.
Major Problems in BC -Line 2.
1. Fender over Flush with Bumper.
2. Fender over flush with A pillar.
3. Fender over flush with FR DR A class.
4. Front frame over Flush with RR DR.
5. T/Lit to C/Lamp Top side over gap, bottom side over gap.
6. Bumper to T/Lid less Gap.
7. C/Lamp over flush with Bumper.
8. FDR-FR DR bottom fewer gaps.
9. Front door down as a whole.

Materials Used:
1. For General Exports and Domestic GA(Galvannealed Steel Sheet),
CR( Cold Rolled Steel Sheet).
2. For European Countries GA only.

Model Specification
Basic
Region

Material

CR
General
Export
GA

EC

Drive
Countries
Type
LHD Argentina,Jordan,Columbia,Paraguay,Ecuador,Bolivai,Madagascar,Morocco,
Ghana, Angola, Guatemal, Costarica.
RHD

India, Indonesia, Mauritius.

LHD

Afghanistan, Sudan, Egypt, Cuba, Syria, Taiwan, Lebanon, UAE, Qatar.

RHD

South Africa.

LHD

Italy,Austria,Spain,Canary Islands,Belgium,Netherlands,Swiss,Greece,
France,Portugal,Denmark,Sweedon,Norway,Germany,Czech
Rep,Turkey,Mexico,Hungary,Croatia,Solvania,Bulgaria.
UK, Ireland, Malta.

GA
RHD

PRESS SHOP
Materials:
Two type of coil materials are used in HMIL Press shop namely
1) CR - Cold Rolled Material
2) GA - Galvanized Material
The Major suppliers of coils are
Suppliers from Korea:
1) Posco-15 %
2) Hysco- 50 %
Indian Suppliers:
1) Bhusan
2) TISCO -20 %
Japanese Supplier:
1) Nippon- 15%

Coil Details:
1) Stock Qty

230-660 Nos

2) Stock Days

15-45 Days

3) Thickness

0.6 to 2 MM

4) Width

420 1630 mm

Coil usage

Supplier

HYSCO
TISCO
NIPPON
POSCO

4000 tons/Month
50%
20%
15%
15%

STAMPING PROCESS FLOW CHART

BLANKING

Coil Storage & Loading

Uncoiler Unit

Blanking

Bender & Shearing

Blank Handling

Washing Unit

Blank Storing

Leveler Unit

Blank Loading

Blanking

Blank Washing

Stamping

Panel checking

Palletizing

Parts Storage

Body Shop
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Press Process:
Press shop contains 2 press namely A1 Line, A2 Line both of 3500 T.
Press process includes Blanking & Stamping.
Blanking Cutting Coils to required Profile.
Stamping.
It includes the following process,
1. Drawing- Uniform metal flow to get the shape.
2. Trimming & Piercing- Trim and Pierces Holes.
3. Flanging & Restriking- Bend the trimmed Holes.
4. Cam form/Piercing- Form the Trimmed Edges.
Panel Inspection:
The Stamped panels are finally inspected for defects with the Guidance of Limit
samples approved By QC.

SEALANT:
The purpose of sealant is to prevent infiltration of water and dust & to have
corrosion resistant-noise & anti-vibration. Sealant is applied in doors and
joints sometimes by Manual, and by automatic application.
TYPES OF SEALANT:
*Spot
*Hemming
*Mastic
*Roof
*Body Panel Reinforcement
*Anti-Vibration pad
*Tape sealant
*Butyl Sealant.

Hemming Sealant:
It is thermosetting sealant that is usually applied on
clinching parts of the panel such as hood, trunk lid,& door.
General characteristics: *High adhesive strength
*Anti-Corrosion
Mastic Sealant:
It is non solvent paste & thermosetting sealant with
principal incredient of synthetic rubber.
Body Panel Reinforcement Sealer;
It is applied outer panel only for Domestic Doors.
Soldering:
Soldering is a method of joining metal parts using an alloy of low melting
point filler material (solder) which has a melting temperature below 450 C
(800 F). Soldering is distinguished from brazing by virtue of a lowertemperature filler metal; it is distinguished from welding by virtue of the
base metal not melting.
In a soldering process, heat is applied to the metal parts, and the alloy metal
is pressed against the joint, melts, and is drawn into the joint by capillary
action and around the materials to be joined by 'wetting action'. After the
metal cools, the resulting joints are not as strong as the base metal, but have
adequate strength, electrical conductivity, and water-tightness for many uses.
Soldering is an ancient technique that has been used practically as long as
humans have been making articles out of metals.

Parts Inspection
The frequent inspection plays a prominent role in deciding the Quality of
parts supplied to assembly of the vehicle from both sourcing namely made
in Plant and from Vendor. To stabilize the Quality of parts in long Run all
necessary parameters need to be carefully studied for delivering a better
product. So stringent standards need to be followed before streamlining the
parts for Mass production. In HMIL to ensure better Parts in Mass
production ISAR is been done for each part to avoid the unnecessary costly
Design Changes with the coordination of cross Functional team.
BIW- Body in white.
Parts Inspection is done on
1. MIP Parts.
2. Vendor Parts.
3. KD Parts.
MIP Parts:
MIP refers to Made in Parts, ie in Press Shop.
MIP are checked for the following,
1. Dimension
2. Appearance
3. Fitment.
Dimensions are checked by using Fixture, ie checking and inspection
fixtures.
Appearance Inspection is done by,
1. Visual
2. Using Oil Stone
3. Hand Feeling

4. Oil.

Revalidation frequency for parts from vendor

CLASSIFICATION

SAFETY/REG.PART

CRITICAL PART

GENERAL PART

Revalidation
frequency

* 3 months

* 6 months

*12 months

ISAR:
The word ISAR stands for Initial Sample Assurance report. It is done
to make the Vendor understand clearly the requirements of HMI i.e.,
specification etc, so as to enable the vendor to supply the parts with
consistent quality to satisfy the final customer requirements. It needs to be
done for
*New Parts
*Modified parts
*Design change
*Sub vendors changed
*Material specification changed
*Mould /Die changed
*Process is Changed
*Factory Shifted
*Surface treatment method is changed
*When tooling is not used for 1year
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*Last supply rejected for the Major Quality problem.

QC team plays a major role in ISAR approval for following parameters.
1) Decision regarding supply Quantity & document submission for
initial approval.
2) Decision regarding AOI parameters & approval.
3) Approval for Initial sample parts.
4) Validation of finished vehicle Quantity.

AOI Preparation:
AOI- Agreement of Information.

QC team from HMI and QC team in charge from Vendor side will
sign A.O.I.
The following requirements are mandatory during AOI.
*No of samples and documents required.
*Important quality Parameters and control parameters.
*Inspection for body & assy parts and frequency of submission of report.
*Limit Samples decision.
*Details of parameter to be included in the assurance report.
*Reference documents required.
*FMEA
*Control plan
*Production capability
*MSA
*SPC
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The following documents shall be submitted at time of first AOI.

*Inspection standard
*Checker, fixture planning sheet.
*Test plan.
The initial AOI shall be finalized before Initial pilot production & final
AOI to be completed before start of Mass production and it will be
preserved in both end for future reference.

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BODY PARTS INSPECTION ACTIVITY

Vendor Report Inspection process

Verification of
Inspection Report
Resp: V.D

V.D team forwards

the report to QC
team

QC team checks the report

& if ok
QC to Give Assy
Fitment confirmation

Fitness and function

check
Resp: QC

Inform VD for
conformity of part
for Mass Production
Resp: QC

Ok

Not ok

Inform Vendor
&V.D for
NOK
corrective action
Resp: QC

Final Improvement validation

Resp: QC

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Every part passes through the same procedure before conforming for mass
production, & (PMT) production Management team is responsible for
supplying the parts to Assembly line.

Vendor parts:
ISAR is done for all vendor parts(Domestic & Import).
Activities to be done by vendor,
1. Instruments & equipments details should be submitted.
2. Variation, repeatability, reproducibility should be given wherever
needed.
3. All dimensions inspections.
4. Material Specifications Test.
5. Appearance Inspection.
6. Engg spec/Performance Test.
7. ISAR
8. Specification change.

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Inspection Method for Vendor parts:

Various Inspection methods are followed to make sure that
there are no any major Discrepancies in the Assembly line.

Lot Inspection:
Monthly Quality reports for all the parts supplied by vendor are
prepared. Top 5 problems are identified and intimated to all part in charges
to ensure that the problems are not repeated. Random lot inspection on daily
basis for top 5 problems of previous months is done regularly.

Self Inspection:
Self Inspection is done before fitment of parts in line and
Operators do self inspection of parts.
Patrol Inspection:
The person in charge for that particular part is responsible to carry out
the inspection considering
Recent Incoming parts defects
Parts Priority

Revalidation/Regular Inspection:
During Mass production, in order to ensure total quality conformance of the
incoming parts, the parts are regularly inspected as per the Inspection
Standard. It is carried out by the vendor and the report for the same is
submitted. Parts in charge verify the same. Parts in charge carry out the
revalidation inspection as per plan. In some cases it may be carried out at

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vendor end or outside. Sample quantity may vary based on lot size
/importance.
MIP Parts Inspection:
After ISAR of MIP the parts are directly sent to production by press shop
after self inspection. QC inspects the panels daily & in Line Inspection on
sample Basis.

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