-PROJECT REPORT-

| Internship |
 -BODY CONSTRUCTION-
FORD INDIA PRIVATE LTD.
VIA S.P. KOIL POST, CHENGALPATTU – 603204

PAGE 1
 About FORD
The Ford Motor Company (commonly
referred to simply as Ford) is
an American multinational automaker
headquartered in Dearborn, Michigan, a
suburb of Detroit. It was founded by Henry
Ford and incorporated on June 16, 1903.
The company sells automobiles and
commercial vehicles under the Ford brand and
most luxury cars under the Lincoln brand.
Ford also owns
Brazilian SUV manufacturer, Troller, and
Australian performance car manufacturer FPV. In the past it has also
produced tractors and automotive components. Ford owns a 2.1% stake
in Mazda of Japan, an 8% stake in Aston Martin of the United
Kingdom, and a 49% stake in Jiangling of China. It also has a number
of joint-ventures, one in China (Changan Ford Mazda), one in Taiwan
(Ford Lio Ho), one in Thailand (AutoAlliance Thailand), one in Turkey
(Ford Otosan), and one in Russia (Ford Sollers). It is listed on the New
York Stock Exchange and is controlled by the Ford family, although
they have minority ownership.
Ford was the first to introduce methods for large-scale
manufacturing of cars and large-scale management of an industrial
workforce using elaborately engineered manufacturing sequences
typified by moving assembly lines; by 1914 these methods were known
around the world as Fordism. Ford's former UK
subsidiaries Jaguar and Land Rover, acquired in 1989 and 2000
respectively, were sold to Tata Motors in March 2008. Ford owned the
Swedish automaker Volvo from 1999 to 2010. In 2011, Ford is continued
the Mercury brand, under which it had marketed entry-level luxury
cars in the United States, Canada, Mexico, and the Middle East since
1938.
During the financial crisis at the beginning of the 21st century, it
was close to bankruptcy, but it has since returned to profitability.

PAGE 2
Ford is the second-largest U.S.-based automaker (preceded by General
Motors) and the fifth-largest in the world based on 2010 vehicle
sales. At the end of 2010, Ford was the fifth largest automaker in
Europe. Ford is the eighth-ranked overall American-based company in
the 2010 Fortune 500 list, based on global revenues in 2009 of
$118.3 billion. In 2008, Ford produced 5.532 million automobiles and
employed about 213,000 employees at around 90 plants and facilities
worldwide. The company went public in 1956 but the Ford family,
through special Class B shares, still retain 40 percent voting rights.

History
Henry Ford's first
attempt at a car
company under his
own name was
the Henry Ford
Company on
November 3, 1901,
which became
the Cadillac Motor
Company on
August 22, 1902,
after Ford left with
the rights to his
name.
The Ford Motor Company was launched in a converted factory in
1903 with $28,000 in cash from twelve investors, most
notably John and Horace Dodge (who would later find their own car
company). During its early years, the company produced just a few
cars a day at its factory on Mack Avenue and later its factory on
Piquette Avenue in Detroit, Michigan. Groups of two or three men
worked on each car, assembling it from parts made mostly by supplier
companies contracting for Ford. Within a decade the company would
lead the world in the expansion and refinement of the assembly

PAGE 3
line concept; and Ford soon brought much of the part production in-
house in a vertical integration that seemed a better path for the era.
Henry Ford was 39 years old when he founded the Ford Motor
Company, which would go on to become one of the world's largest and
most profitable companies
After the first gasoline powered automobile was created in the
year 1885 by German inventor Carl Benz (Benz Patent-Motorwagen),
more efficient production methods were needed to make the
automobile affordable for the middle-class; which Ford contributed to,
for instance by introducing the first moving assembly line in 1913 at
its factory in Highland Park.
Between 1903 and
1908 Ford produced
the Models A, B, C,
F, K, N, R, and S,
most of which sold
in the hundreds or
few thousands a
year. In 1908 Ford
introduced the
mass-
produced Model T,
which would sell in
the millions. In
1927, Ford replaced
the T with the Model A, the first car with safety glass in the
windshield. Ford launched the first low priced V8 engine powered car
in 1932.
The creation of a scientific laboratory in Dearborn, Michigan in
1951, doing unfettered basic research, led to Ford's unlikely
involvement in superconductivity research. In 1964 Ford Research
Labs made a key breakthrough with the invention of a
superconducting quantum interference device or SQUID.

PAGE 4
 Ford India
Ford manufactures and exports vehicles and engines made at its
integrated manufacturing facilities in Chennai, Tamil Nadu and
Sanand, Gujarat.

Since its entry in India in 1995, Ford has invested more than US$ 2
billion to expand its manufacturing facilities and sales & service
footprint to meet demand in one of the world's fastest-growing auto
markets. Ford India’s integrated manufacturing facility at Maraimalai
Nagar, near Chennai, produces its award-winning range of products
including the Ford EcoSport and Ford Endeavour.

As part of its overall commitment, Ford inaugurated its US$ 1 billion

state-of-the-art integrated manufacturing facility in Sanand, Gujarat in
March 2015. With Sanand being operational, Ford India has doubled its
annual installed manufacturing capacity to 610,000 engines and
440,000 vehicles. The sub-four-metre compact sedan, Ford Figo
Aspire, became the first car to roll out from the new Ford Sanand
plant. The plant also manufactures new Figo hatchback.

Ford’s biggest-ever product line-up in India today offers a vehicle to

suit the needs of nearly every consumer. In 2016, Ford has also given
Indian consumers their first opportunity to own the iconic Ford
Mustang. Debuting ahead of the Delhi Auto Expo 2016 and set to hit
Indian showrooms later this year, the new Mustang is all set to bring
the world-class performance and refinement of Ford’s iconic pony car
to India’s roads.

As part of its strategy to Make in India for India and the World, Ford
continues to strengthen India as a center of excellence for small cars
and low displacement engines. The company has embarked on an
accelerated export strategy and presently, exports Figo, Aspire, and
EcoSport to over 40 markets around the world.

PAGE 5
 Along with introducing new products, Ford continues to grow
closer to customers with the continued expansion of its nationwide
dealership network as well as world-class after-sales offerings.
Presently, Ford has more than 376 sales and service outlets in 209
cities across India. To enhance affordability and accessibility, Ford has
introduced many pioneering initiatives that reduce the cost of
ownership including the Sub-assembly of parts, Pan-India Roadside
Assistance, and Mobile Service Support. To ensure total transparency
in service costs, Ford also introduced a unique Service Price Promise,
which allows customers to calculate the vehicles’ periodic maintenance
costs even before booking the service at the dealership.

Ensuring customer convenience, Ford has expanded the availability of

Ford Genuine Parts with the appointment of distributors in
Maharashtra, Goa, Karnataka, Kerala, Delhi, Tamil Nadu, AP, and
Telangana.

Ford’s presence in India includes Ford Credit India, which started

dealer wholesale inventory and retail financing in 2015 as a non-

PAGE 6
banking financial company. With five decades of global experience,
Ford Credit’s operations span in as many as 100 countries where it has
emerged as a preferred automotive financier for both Ford customers
as well as dealers.

Ford Credit is known for its reliable and transparent loan products at
competitive rates, flexible terms, and outstanding customer service.

Continuing to generate employment and help the economy, Ford’s

operations currently employ more than 14,000 hard-working,
dedicated men and women across its operations in India which also
include Global Business Services, with offices in Chennai, New Delhi,
and Coimbatore.

Registered as Ford Motor Pvt Ltd. (FMPL) as a legal entity, Global

Business Services provide innovative solutions to nearly every Ford
locations around the world in areas of Information Technology,
Product Engineering, Finance and Accounting, Automotive Financing,
Material, Planning & Logistics, Marketing Sales and Service, Analytics,
and Purchasing.

Driving innovation from India, Ford recently announced plans to build

a new global engineering and technology center in Chennai. Besides
the establishment of a global engineering and technology center, the
new Ford campus spread across 28 acres will host operations of Ford
Global Business Services in areas of IT, Product Engineering, Finance
and Accounting, Data Analytics, Manufacturing among others.

Ford’s commitment to India is not just business centric. At the heart of

our business plans are people and communities. Going further with its
Better World philosophy, Ford India in association with Ford Motor
Company Fund announced ‘Operation Better World,' with the
endeavour to address issues related to Education, Sustainability and
Auto Safety around communities where it operates.

PAGE 7
 CHENNAI FORD PLANT
• It was 1998 when Ford started a new branch in Chennai i.e., Ford
Chennai Vehicle Assembly Plant.
• The first production of this plant was FORD IKON which
successfully happened in the year 2000.
• In next few years it started producing other model like FORD
FIESTA.
• In 2004, it included FORD ENDEAVOUR in its production.
• This Plant also included other models like FORD FIGO, FORD
ECOSPORT, FORD ENDEAVOUR in its manufacturing and
production units.
• In 2010, FORD ECOSPORT took the lead and other few models
are stopped.
• At present, the Plant has two models in its manufacturing and
production units.
❖ FORD ECOSPORT

❖ FORD ENDEAVOUR

• In the year 2008, Engine Plant was established.

Shops Overview
The Plant comprises of various shop floors for complete outcome
of any Car. They are,

• Blanking & Stamping

• Body Shop
• Paint Shop
• TCF

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 Finally, Car undergoes various track tests, water test etc., before
it gets into the Market.

BODY CONSTRUCTION SHOP

Car Body gets shape. It is also called as Body Shop. It comprises
of various zones namely,

• UNDER BODY

The Bottom part of Car Body is called Under Body. It includes

assembly of Engine Compartment, Front Floor and Rear Floor
which is carried out in various stages at several stations.

• SIDE BODY

Sides of Car Body which are assembled to the Under Body are
called Body Sides (LH & RH). Making of LH and RH Body Sides
takes place in this zone in various stages at several stations.

• FRAMING

Assembling of Body Sides (LH & RH) and Roof to the Under
Body takes place in this zone in various stages at several stations.

• CLOSURES

Front and Rear Doors (LH & RH), Hood and Swing Gate
constitute Closures. Making of Front and Rear Doors (LH & RH),
Hood and Swing Gate is carried out in this zone in various stages
at several stations.

• MAIN LINE

Assembling of Closures to the Framed Body part takes place in

this zone in various stages at several stations.

PAGE 9
 • METAL FINISHING

Checking of Defects by inspection and their Rectification by

rework, if any are present is carried out in this zone in various
stages at several stations. It is explained in detail in following
pages.

Processes involved in BODY SHOP

• Blanking (metalworking), a metalworking process to
form the rough shape of a sheet metal workpiece.

• Stamping (also known as pressing) is the process of

placing flat sheet metal in either blank or coil form into
a stamping press where a tool and die surface forms the
metal into a net shape

• Sealer application is a process of applying Sealant

which is a substance used to block the passage of fluids
through the surface or joints or openings in materials

• Spot Welding is a process in which contacting metal

surface points are joined by the heat obtained from
resistance to electric current. It is a subset of electric
resistance welding

• Stud Welding is a technique similar to flash welding

where a fastener or specially formed nut is welded onto
another metal part, typically a base metal or substrate

• MIG Welding is a welding process in which an electric

arc forms between a consumable wire electrode and the

PAGE 10
 workpiece metal(s), which heats the workpiece
metal(s), causing them to melt and join

• Clinching is a method for mechanically joining sheet

metal of different thickness and properties in which the
two plates to be joined undergo plastic deformation

• Hemming is the process in which the edge is rolled

flush to itself

• Surface Grinding is used to produce a smooth finish

on flat surfaces

• Fixing (Bolts and Nuts)

• Visual Inspection

• Rectification of Defects

-Under Body-
Comprises of Engine Compartment, Front Floor and Rear Floor.

1. Engine Compartment
Apron, Front Bumper and Dash panel constitute Engine compartment. It
comprises a total of 7 stations out of which 4 are manual and 3 are automated
stations.

2. Dash Panel
One Stamped dash part is applied sealer and above this another sealer applied
stamped dash part and spot welded. Child parts such as Brake booster, Cross
member and Cowl top etc., are added and then spot welded. Dash panel is now
ready for further assembly. All the above process is done in a total of 9 stations.

PAGE 11
 Manual

Station 1: Housing and Front rail (LH & RH) together constituting ‘Apron’ are
attached with the help of spot welding and thus Aprons (LH & RH) are ready for further
assembly.

Station 2: Front Bumper is attached to LH and RH aprons by spot welding.

Station 3: Dash panel takes its place in above assembly and spot welded.

Station 4: Re-spot welding takes place.

Automated

Station 5: A pair of robots carries out re-spot welding.

Station 6: A pair of robots carries out re-spot welding.

Station 7: A pair of robots carries out re-spot welding.

Now the Engine Compartment is ready for further Assembly.

3. Rear Floor
It is the Floor part located at rear end. There is a total of 12 stations.

Sub-assembly - 5 stations

Station 1: Rear floor part is attached to the stamped part and spot welded.

Station 2: Re-spot welding is carried out.

Station 3: Child parts are attached and spot welded.

Station 4: 4 cargo hooks are fixed with the help of bolts.

Station 5: Re-spot welding is carried out.

Main Line - 4 stations

Station 1: Side members are attached to the above assembly and spot welded.

Station 2: Cross ring is added and spot welded.

Station 3: Back panel takes its place and spot welded.

Station 4: Re-spot welding takes place.

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In next 3 stations, 3 pairs of robots carry out re-spot welding. Now Rear Floor is ready for
further Assembly.

4. Front Floor
It is the floor part located at the front end. It comprises a total of 7 stations out of which 5
are manual and 2 are automated stations.

Manual - 5 stations

Station 1: Front part is attached to the stamped part and spot welded.

Station 2: Cross member is added and spot welded.

Station 3: Seat hooks are fixed with the help of bolts.

Station 4: Re-spot welding takes place.

Station 5: Child parts are added and spot welded.

Auto - 2 stations

In these 2 stations, 2 pairs of robots carry out re-spot welding. Now the Front Floor is
ready for further Assembly.

5. Geo Station
Engine Compartment, Front Floor and Rear Floor are brought into single station from
three different lines and assembled with the help of automated spot welding. Now Under
Body is ready.

With the help of Electro Mono System, Under Body is sent to lifter which lifts and takes it
to the Under Body main line. This under Body main line consists of 7 pairs of robots which
carries out re-spot welding.

After the above process, Under Body is fitted to the ‘Ski bar’ to facilitate the shuttle
movement throughout until the Wheel assembly.

-Side Body-
Comprises of body sides (LH & RH) which are to be framed with Under body to which
roof and closures are assembled.

LH:
No. of stations: 11 (BS – Body Side) (SA – Side Assembly)

PAGE 13
 1. Front Ring
Station 1: BS 03 : B-pillar, A-pillar, rocker and roof rail are assembled and spot
welded.

Station 2: BS 05 : T-part is attached to the above assembly and spot welded.

Station 3: BS 07 : Cowl top is placed on top of the assembly and spot welded.
Re-spot welding also takes place. Front Ring is ready for side assembly.

2. Rear Ring
Station 4: BS 10 : To the stamped Wheel arch housing, wheel arch inner is
attached with the help of sealer and spot welded.

Station 5: BS 20 : The above assembly is placed on D-pillar and spot welded.

Further C-pillar is added and spot welded. Re-spot welding is done in 4 stations further.

Rear Ring is ready for side assembly.

3. Side Assembly
Station 6: SA 10 : To the stamped outer periphery of body side, front ring is
assembled.

Spot welding is done further.

Station 7: SA 20 : Additional small parts are welded to the above assembly.

Station 8: SA 30 : Rear ring is welded to the above assembly.

Now manual re-spot welding takes place in 3 stations.

Station 9: SA 40 : Auto re-spot welding takes place with the help of 4 pairs of
robots.

Station 10: SA 50 : Clinching process is carried out. It is done with Electro Mono
System.

Station 11: SA 60 : Buy-off takes the role.

Now the Body Side (LH) is ready for further assembly.

RH:
No. of stations : 11 (BS – Body Side) (SA – Side Assembly)

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 4. Front Ring
Station 1: BS 03 : B-pillar, A-pillar, rocker and roof rail are assembled and spot
welded.

Station 2: BS 05 : T-part is attached to the above assembly and spot welded.

Station 3: BS 07 : Cowl top is placed on top of the assembly and spot welded.
Re-spot welding also takes place. Front Ring is ready for side assembly.

5. Rear Ring
Station 4: BS 10 : To the stamped Wheel arch housing, wheel arch inner is
attached with the help of sealer and spot welded.

Station 5: BS 20 : The above assembly is placed on D-pillar and spot welded.

Further C-pillar is added and spot welded. Re-spot welding is done in 4 stations further.

Rear Ring is ready for side assembly.

6. Side Assembly
Station 6: SA 10 : To the stamped outer periphery of body side, front ring is
assembled.

Spot welding is done further.

Station 7: SA 20 : Additional small parts are welded to the above assembly.

Station 8: SA 30 : Rear ring is welded to the above assembly.

Now manual re-spot welding takes place in 3 stations.

Station 9: SA 40 : Auto re-spot welding takes place with the help of 4 pairs of
robots.

Station 10: SA 50 : Clinching process is carried out. It is done with Electro Mono
System.

Station 11: SA 60 : Buy-off takes the role.

Now the Body Side (RH) is ready for further assembly.

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 -FRAMING-
Operation follows,

Underbody, Body side (L.H & R.H) and Roof Assembly.

No. of Stations-13

Manual - 4 Auto - 9
Operation (MB-Main Buck)

Manual Stations

Station 1: MB 05 : Brings Underbody ready for Assembly.

Station 2: MB 10 : Joining body sides to Underbody – Tabbing Process.

Station 3: MB 20 : To the above assembly,4 ‘anti flutter sealer’ applied bows

namely Front , Rear and 2 Middle Bows are attached to facilitate roof assembly.

Also Cowl Part is attached below wind shield fitting area – Tabbing Process.

Station 4: MB 30 : Idle Station (No work will be done).

Auto Stations

Station 5: MB 40 : Gripper holds the above assembly to maintain Dimensional

Accuracy (±5% tolerance) and welded for Key Spots to maintain that Dimensional
Accuracy throughout.

Station 6: MB 50 : Re-spot welding above assembly. Here Robot changes

equipment for ease of Welding.

Station 7: MB 60 : Gripper helps in Roof fixing and further spot welded.

Station 8: MB 70 : Back panel at bottom , 2 small parts under cowl part are
attached through automation by Shot Guns and spot welded.

Station 9: MB 80 : Re-spot welding takes place.

Station 10: MB 90 : Re-spot welding takes place.

Station 11: MB 100 : Re-spot welding takes place.

PAGE 16
Station 12: MB 110 : Re-spot welding takes place.

Station 13: Vertical Drop Lifter : Lifts the assembly for visual checkpoint.

And further brought down for Re-spot welding (2 manual -> 2 auto -> 2 manual).

Framing is completed and the ‘Framed Assembly’ boards another line for further
processing.

-CLOSURES-
Closure includes making of front and rear doors, hood and swing gate.

1. Door

Front Door
LH & RH Front

Rear Door
Front
LH:
Front Door(FD)

Consists of 2 parts namely Inner and Outer parts.

No. of Stations : 5

Station 1: FD 10 : Atbelt , Upper and lower Hinge supports are attached to the
Inner part . Sealer is applied in attachment of Atbelt. Spot welding is done further.

No. of Spots -- 12.

Station 2: FD 15 : Check arm , C-channel are attached . Sealer is applied during

attachment. Spot Welding is done further.

No. of Spots -- 12.

Station 3: FD 20 : A-channel , B-channel are attached . Spot welding is done

further.

No. of Spots -- 13.

PAGE 17
Station 4: FD 22 : Re-spot welding is carried out.

No. of Spots -- 15.

Station 5: FD 25 : Outer belt and Strainer are attached . Spot welding is done
further.

No. of Spots -- 15.

The Outer part and Inner part are assembled with the help of automation. Sealer is
applied to the outer part in 2 steps. First to outline of window with less thickness and then
in the middle with more thickness. This outer part is supported by Robotic holder and
then the inner part is brought and assembled.

Next operation is ‘Hemming’ an operation similar to Clinching. Hemming is carried

out in 2 steps. First hemming includes door outline and second includes window
periphery. Spot welding is done further (5 Spots - Auto). Upper and Lower Hinges are
attached to their supports. Then Visual Checking takes place and further Grinded if
needed. Thus, the LH Front Door is ready.

Rear Door(RD)

Consists of 2 parts namely Inner and Outer parts.

No. of Stations : 4

Station 1: RD 10 : B-channel , Upper and lower Hinge supports are attached to

the Inner part. Sealer is applied in attachment of channel. Spot welding is done further.

No. of Spots -- 9.

Station 2: RD 12 : Check arm , C-channel are attached . Sealer is applied during

attachment. Spot Welding is done further.

No. of Spots -- 13.

Station 3: RD 15 : A-channel , Strainer are attached . Spot welding is done

further.

No. of Spots -- 17.

Station 4: RD 20 : Outer belt and small Strainer are attached . Spot welding is
done further.

No. of Spots -- 12.

PAGE 18
 The Outer part and Inner part are assembled with the help of automation. Sealer is
applied to the outer part in 2 steps. First to outline of window with less thickness and then
in the middle with more thickness. This outer part is supported by Robotic holder and
then the inner part is brought and assembled.

Next operation is ‘Hemming’ an operation similar to Clinching. Hemming is carried

out in 2 steps. First hemming includes door outline and second includes window
periphery. Spot welding is done further (5 Spots - Auto). Upper and Lower Hinges are
attached to their supports. Then Visual Checking takes place and further Grinded if
needed. Thus, the LH Rear Door is ready.

RH:
Front Door(FD)

Consists of 2 parts namely Inner and Outer parts.

No. of Stations : 5

Station 1: FD 10 : Atbelt , Upper and lower Hinge supports are attached to the Inner
part . Sealer is applied in attachment of Atbelt. Spot welding is done further.

No. of Spots -- 12.

Station 2: FD 15 : Check arm , C-channel are attached . Sealer is applied during

attachment. Spot Welding is done further.

No. of Spots -- 12.

Station 3: FD 20 : A-channel , B-channel are attached . Spot welding is done further.

No. of Spots -- 13.

Station 4: FD 22 : Re-spot welding is carried out.

No. of Spots -- 15.

Station 5: FD 25 : Outer belt and Strainer are attached . Spot welding is done further.

No. of Spots -- 15.

The Outer part and Inner part are assembled with the help of automation. Sealer is
applied to the outer part in 2 steps. First to outline of window with less thickness and then
in the middle with more thickness. This outer part is supported by Robotic holder and
then the inner part is brought and assembled.

PAGE 19
 Next operation is ‘Hemming’ an operation similar to Clinching. Hemming is carried
out in 2 steps. First hemming includes door outline and second includes window
periphery. Spot welding is done further (5 Spots - Auto). Upper and Lower Hinges are
attached to their supports. Then Visual Checking takes place and further Grinded if
needed. Thus, the RH Front Door is ready.

Rear Door(RD)

Consists of 2 parts namely Inner and Outer parts.

No. of Stations : 4

Station 1: RD 10 : B-channel , Upper and lower Hinge supports are attached to the
Inner part. Sealer is applied in attachment of channel. Spot welding is done further.

No. of Spots -- 9.

Station 2: RD 12 : Check arm , C-channel are attached . Sealer is applied during

attachment. Spot Welding is done further.

No. of Spots -- 13.

Station 3: RD 15 : A-channel , Strainer are attached . Spot welding is done further.

No. of Spots -- 17.

Station 4: RD 20 : Outer belt and small Strainer are attached . Spot welding is done
further.

No. of Spots -- 12.

The Outer part and Inner part are assembled with the help of automation. Sealer is
applied to the outer part in 2 steps. First to outline of window with less thickness and then
in the middle with more thickness. This outer part is supported by Robotic holder and
then the inner part is brought and assembled.

Next operation is ‘Hemming’ an operation similar to Clinching. Hemming is carried

out in 2 steps. First hemming includes door outline and second includes window
periphery. Spot welding is done further (5 Spots - Auto). Upper and Lower Hinges are
attached to their supports. Then Visual Checking takes place and further Grinded if
needed. Thus, the RH Rear Door is ready.

2. Hood

PAGE 20
 It consists of 2 parts namely Inner and Outer parts.

Inner part - 2 stations (Fixtures)

Station 1: 5G010 : To the stamped inner panel, Striker, Upper and Lower child
parts are added and spot welded.

No. of spots – 12

Station 2: 5G015 : To the above assembly, 2 hinge parts are added and spot welded.

No. of spots – 12

Now Hood inner part is ready for further assembly.

Assembly - 5 stations (Robot shell)

• One robot holds the inner part and applies sealer to it.
• Another robot holds the outer part and applies adhesive sealer to the inner side.
• Both the parts are brought to clinching bed 1 where their assembling and
preclinching is done.
• It is transferred to clinching bed 2 where full clinching is done.
• This is transferred to the unloading bed.
From the unloading bed, it is moved to buy off table where checking of surface
defects takes place and rectified if any are present.
Now Hood is ready for further assembly.

3. Swing Gate
It consists of 2 parts namely Inner and Outer parts.

Inner part - 6 stations (fixtures)

Station 1: 5F010 : To the stamped inner panel, upper, lower hinges and latch are
added and spot welded.

No. of spots – 17

Station 2: 5F015 : To the above assembly, stud part or pivot bracket is added and
spot welded.

No. of spots – 9

PAGE 21
Station 3: 5F020 : Spare wheel upper and lower support brackets are added to the
above assembly and spot welded.

No. of spots – 21

Station 4: 5F028 : Re-spot welding takes place.

No. of spots – 17

Station 5: 5F025 : Re-spot welding takes place.

No. of spots – 18

Station 6: 5F029 : Re-spot welding takes place.

No. of spots – 13

Assembly - 5 stations (Robot shell)

• One robot holds the inner part and applies sealer to it.
• Another robot holds the outer part and applies adhesive sealer to the inner side.
• Both the parts are brought to clinching bed 1 where their assembling and
preclinching is done.
• It is transferred to clinching bed 2 where full clinching is done.
• Now with the help of pedestrial welding machine, final spot welding (21 spots) is
done.
• This is transferred to the unloading bed where stud welding (1 stud) takes place.
• 5F060: Upper and lower hinges are clamped and fixed in this station.
From the unloading bed, it is moved to buy off table where checking of
surface defects takes place and rectified if any are present.
Now Swing Gate is ready for further assembly.

-Main Line-
Closures i.e., Front and Rear doors (LH & RH), Hood and Swing Gate along with
fenders are assembled to the Framed Body. The Process includes MIG Welding, Fitting,
Adjusting and Checking.

No. of Stations: 17 (ML – Main Line)

Station 1: ML 00 : Checking for Burrs, Dents etc., and their removal takes place.

Station 2: ML 10 : MIG Welding is carried out. Wherever Spot Welding is not

possible, MIG Welding takes the role.

PAGE 22
Station 3: ML 20 : Hood hinge fitment with the help of Bolts. Back panel is
Grinded if needed.

Station 4: ML 30 : Rear doors (LH & RH) fitment is carried out with the help of
Bolts.

Station 5: ML 40 : Rear doors’ adjustment takes the role with the help of
Hammer and Chisel.

Station 6: ML 50 : Front doors (LH & RH) fitment is carried out with the help of
Bolts.

Station 7: ML 60 : Front doors’ adjustment takes the role with the help of
Hammer and Chisel.

Station 8: ML 70 : Fenders (LH & RH) are loaded.

Station 9: ML 80 : Fenders’ fitment takes place with the help of Bolts.

Station 10: ML 90 : Fenders’ adjustment takes place to maintain distance (1.9 to

4.9mm) between front door and fender.

Station 11: ML 100 : Hood fitting is done to hood hinges with the help of hood Jig
and Bolts.

Station 12: ML 110 : Hood adjustment and Swing Gate fixing with Bolts is carried
out. Slave tool helps in hood adjustment.

Station 13: ML 120 : Swing Gate adjustment is done.

Station 14: ML 130 : Buy-off (Checking) takes the role. Checking of front, rear
doors and fenders is carried out.

Station 15: ML 140 : Empty station. Nothing will be done.

Station 16: ML 150 : Empty station. Nothing will be done.

Station 17: ML 160 : Final buy-off. Final checking of closures is carried out.

-Metal Finishing-
This is the final zone in the Body Shop where outer and inner surface defects such
as dents, dings, weld defects, damage etc., are checked and rectified if any are present.

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 Metal Finishing follows 6 stages in which Inspection (Visual, Touch & Feel) and
Rework are carried out.

Stage 1: Outer periphery (Fender, Front & Rear Doors, Quarter Rail) of Lower Deck of
body (LH & RH) is inspected.

Stage 2: Inner periphery of Lower Deck of body (LH & RH) and some part of Swing
Gate is inspected.

Stage 3: Upper Deck of body (Window part, Roof, Hood, Swing Gate, Header) is
inspected.

Stage 4: Rework starts from here. It includes rectifying of defects with the help of Dent
puller, Buffing machine, Flat Rough File, Hammer, Belt Grinding machine, Chisel, Punch
and hook.

Stage 5: It is the Validation stage. It includes checking of minor and major defects and
validates Whether it is ‘OK’ or ‘NOT OK’. If ‘OK’ it is sent to Body Bank, Otherwise to
Offline Conveyer.

Stage 6: VIN (Vehicle Identification Number) tracking is carried out manually with the
help of scanner and then noted in a register.

After stage 6, body goes to Body Bank if it is ‘OK’ or else it goes to Offline Conveyer
if it is ‘NOT OK’.

Now “BODY CONSTRUCTION” is completed. Then it follows further processing

like Paint and TCF.

Reference
• http://corporate.ford.com/history.html
• https://en.wikipedia.org/wiki/

-Thank You-

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