Automotive Manufacturing Processes

A comprehensive and dedicated guide to automotive production lines, The Automotive Body Manufacturing Systems and Processes addresses automotive body processes from the stamping operations through the final assembly activities. To begin, it discusses current metal forming practices, including stamping engineering, die development, and dimensional validation, and new innovations in metal forming, such as folding based forming, super-plastic, and hydro forming technologies. The first section also explains details of automotive spot welding (welding lobes), arc welding, and adhesive bonding, in addition to flexible fixturing systems and welding robotic cells. Guiding readers through each stage in the process of automotive painting, including the calculations needed to compute the number of applicators and paint consumption based on vehicle dimensions and demand, along with the final assembly and automotive mechanical fastening strategies, the book's systematic coverage is unique. The second module of the book focuses on the layout strategies of the automotive production line. A discussion of automotive aggregate planning and master production scheduling ensures that the reader is familiar with operational aspects. The book also reviews the energy emissions and expenditures of automotive production processes and proposes new technical solutions to reduce environmental impact. Provides extensive technical coverage of automotive production processes, discussing flexible stamping, welding and painting lines Gives complete information on automotive production costing as well as the supplier selection process Covers systems from the operational perspective, describing the aggregate and master production planning Details technical aspects of flexible automotive manufacturing lines Methodically discusses the layout and location strategies of automotive manufacturing systems to encompass the structural elements Features topic-related questions with answers on a companion website

Automotive Manufacturing Processes discusses basic principles and operational procedures of automotive manufacturing processes, issues in the automotive industry like material selection, and troubleshooting. Every chapter includes specific learning objectives, multiple-choice questions to test conceptual understanding of the subject and put theory into practice, review questions, solved problems, and unsolved exercises. It covers important topics including material decision-making processes, surface hardening processes, heat treatment processes, effects of friction and velocity distribution, the metallurgical spectrum of forging, and surface finishing processes. Features: Discusses automotive manufacturing processes in a comprehensive manner with the help of applications. Provides case studies addressing issues in the automotive industry and manufacturing operations in the production of vehicles. Discussion on material properties while laying emphasis on the materials and processing parameters. Covers applications and case studies of the automotive industry. The text will be useful for senior undergraduates, graduate students and academic researchers in areas including automobile engineering, industrial and manufacturing engineering and mechanical engineering.

The evolution and execution of automotive manufacturing are explored in this fundamental manual. It is an excellent reference for entry level manufacturing engineers and also serves as a training guide for nonmanufacturing professionals. The book covers the major areas of vehicle assembly manufacturing and addresses common approaches and procedures of the development process. Having held positions as both a University Professor and as a Lead Engineering Specialist in industry, the author draws on his experience in both theory and application to fill the gap between academic research and industrial practices. This concisely written, comprehensive review discusses the sophisticated principles and concepts of automotive manufacturing from development to applications and includes: 250 illustrations and 90 tables. End-of-chapter review questions. Research topics for in-depth case studies, literature reviews, and/or course projects. Analytical problems for additional practice. Directly extracted and summarized from automotive manufacturing practices, this book serves as an essential manual. The subject is complemented by the author’s first book, Automotive Vehicle Assembly Processes and Operations Management, which provides even greater depth to the complex endeavor of modern automotive manufacturing.

Proven technologies and processes are explored in this examination of modern automotive manufacturing. Fundamentals and applications, as well as new advances are discussed as the author bridges the gap between academic research and industrial practice. Having held positions as both a University Professor and as a Lead Engineering Specialist in industry, the author presents a concise understanding that reflects both technical and managerial perspectives with the aim of providing improvement through practical methods. Each chapter includes review questions and research topics, and, in addition, analysis problems are often included that comprehensively address: • Automotive Industry and Competition • Manufacturing Operations • Joining and Paint Processes • Production Operations and Quality Management • Performance Improvement Directly extracted and summarized from automotive manufacturing practices, this book serves as a fundamental manual. The subject is complemented by the author’s second book, Manufacturing System and Process Development for Vehicle Assembly, which provides even greater depth to the subject of modern automotive manufacturing.

A comprehensive and dedicated guide to automotive production lines, The Automotive Body Manufacturing Systems and Processes addresses automotive body processes from the stamping operations through the final assembly activities. To begin, it discusses current metal forming practices, including stamping engineering, die development, and dimensional validation, and new innovations in metal forming, such as folding based forming, super-plastic, and hydro forming technologies. The first section also explains details of automotive spot welding (welding lobes), arc welding, and adhesive bonding, in addition to flexible fixturing systems and welding robotic cells. Guiding readers through each stage in the process of automotive painting, including the calculations needed to compute the number of applicators and paint consumption based on vehicle dimensions and demand, along with the final assembly and automotive mechanical fastening strategies, the book's systematic coverage is unique. The second module of the book focuses on the layout strategies of the automotive production line. A discussion of automotive aggregate planning and master production scheduling ensures that the reader is familiar with operational aspects. The book also reviews the energy emissions and expenditures of automotive production processes and proposes new technical solutions to reduce environmental impact. Provides extensive technical coverage of automotive production processes, discussing flexible stamping, welding and painting lines Gives complete information on automotive production costing as well as the supplier selection process Covers systems from the operational perspective, describing the aggregate and master production planning Details technical aspects of flexible automotive manufacturing lines Methodically discusses the layout and location strategies of automotive manufacturing systems to encompass the structural elements Features topic-related questions with answers on a companion website

This book presents topics on monitoring and evaluation of production processes in the automotive industry. Regulation of production processes is also described in details. The text deals with the implementation and evaluation of these processes during the mass production of components useful in the automotive industry. It evaluates the effects and results achieved after implementation in practice. The book takes into account the different methodologies of the world's automakers and applicable standards, such as standard EN ISO 9001 and the requirements of VDA and ISO/TS 16949. The content is used to those working with the development, production and quality control of new products in the demanding automotive industry. The information provided may also be useful to engineers and technical staff in organizations working with series production and production of spare parts for the automotive and other demanding industries. The content presented was written based on discussions with various companies and organizations, such as Magna Steyr (Graz, Austria), Ford (Cologne, Germany; Prague, CZ), GM Powertrain (Győr, Hungary), VW (Škoda), ZF (Passau, Friedrichshafen, Germany), Bosch-Rexroth AG (Fellbach, Germany), John Deere (Mannheim, Germany; USA), Claas (Paderborn, Germany), Allison Transmission (USA), Landini (Reggio Emilia, Milan, Italy), Timken Polska (Sosnowiec, Poland), SNR France (Annecy, France), Sweden SKF Group (Lutsk, Ukraine), ZVL Ltd. (Hattingen, Germany), ZVL SpA (Milano, Italy), FAG Schaeffler Group (Debrecen, Hungary), VPZ (Vologda, Russia), ZKL OJSC (Brno, CZ), ZVL Auto Company Ltd. (Prešov, Slovakia), ZVL (Žilina, Slovakia), MAN (Munich, Germany), FTE Automotive (Kerpen, Germany), Rösler (Untermerzbach, Germany; Vienna, Austria), Spaleck (Bocholt, Germany) and Caterpillar (USA). This comprehensive study was supported by grant VEGA 1/0409/13.

This volume of the series ARENA2036 compiles the outcomes of the first Stuttgart Conference on Automotive Production (SCAP2020). It contains peer-reviewed contributions from a theoretical as well as practical vantage point and is topically structured according to the following four sections: It discusses (I) Novel Approaches for Efficient Production and Assembly Planning, (II) Smart Production Systems and Data Services, (III) Advances in Manufacturing Processes and Materials, and (IV) New Concepts for Autonomous, Collaborative Intralogistics. Given the restrictive circumstances of 2020, the conference was held as a fully digital event divided into two parts. It opened with a pre-week, allowing everyone to peruse the scientific contributions at their own pace, followed by a two-day live event that enabled experts from the sciences and the industry to engage in various discussions. The conference has proven itself as an insightful forum that allowed for an expertly exchange regarding the pivotal Advances in Automotive Production and Technology.