IN PLANT TRAINING REPORT

INPLANT TRAINING REPORT AT VISTEON AUTOMOTIVE SYSTEMS INDIA PVT LTD.

RAHUL JAYASURYA A.SRIRAM DEPT. OF MECHATRONICS SRM UNIVERSITY CHENNAI.

By Rahul Jayasurya & A.Sriram

Page 1

IN PLANT TRAINING REPORT

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 as a 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 .
By Rahul Jayasurya & A.Sriram Page 2

IN PLANT TRAINING REPORT

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 interior plastic 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
By Rahul Jayasurya & A.Sriram Page 3

IN PLANT TRAINING REPORT

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
By Rahul Jayasurya & A.Sriram Page 4

IN PLANT TRAINING REPORT

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 y y y High durability and Life Corrosion protection Good appearance and Aesthetics 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.
By Rahul Jayasurya & A.Sriram Page 5

IN PLANT TRAINING REPORT

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 <2% , but radically affect the properties of the systems. Types of Paints: y y y y y Decorative Interior & Exterior Floor & Wood Industrial Special

Application of Paint: Brush, Spray, Dip, Roller, Powder Coating, Fluidized, and Electrostatic. However spray painting is carried majorly than that of the other methods for the application of the paints. Paint Defects: y y y y Loss of Gloss Cracking and Peeling Striping and blistering Water marking and spotting

Altogether in order to complete the painting process of a single carriage of painting. The process flow diagram involved with the painting of the manufactured parts is shown below.

By Rahul Jayasurya & A.Sriram

Page 6

IN PLANT TRAINING REPORT

Inspection

Curing

Flash Off

Clear Coat

Clear Flash Off

Basecoat

Wipe/Air blow

Deribb

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
By Rahul Jayasurya & A.Sriram Page 7

IN PLANT TRAINING REPORT

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 are checked 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 parts that 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.
By Rahul Jayasurya & A.Sriram Page 8

IN PLANT TRAINING REPORT

Receiving Granules Moulding

Receiving Child Parts

Vent Assembly

Effort Checking

Gauge Inspection

Inspection Stages

Visual Inspection

Packing

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 for assembling 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 y y y y Seal shutter assembly Seal shutter and Shutter control assembly with case Case and housing assembly Link & louver assembly with housing 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.

By Rahul Jayasurya & A.Sriram

Page 9

IN PLANT TRAINING REPORT

Glove Box Assembly: The process flow diagram involved in this section is shown below.

Lock Assembly

Inner part and Lock assembly

Bumpstop assy and Pokayoke checking

Ultrasonic Vibration Welding

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. Molding Door Welding Weather Flaming Door Kimikomi Fabric

Glue Spray Fabric

Assembly Child Parts

Pokayoke Visual Inspection

By Rahul Jayasurya & A.Sriram

Page 10

IN PLANT TRAINING REPORT

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.
Milling and

Receiving Granules

Molding

Painting

Nozzle Welding

Clip Assembly

Hole punching

Dispatch

Final Inspection

Pokayoke Inspection

Fabric Welding

Duct Welding

Chute Welding

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
By Rahul Jayasurya & A.Sriram Page 11

IN PLANT TRAINING REPORT

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.

By Rahul Jayasurya & A.Sriram

Page 12