AUTOMOTIVE
ASSEMBLY PROCESSES
John L. Evans, Ph.D.
AUTOMOTIVE SUPPLY CHAIN
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SHEET METAL
POWERTRAIN (ENGINE & TRANSMISSION)
INTERIOR (SEATS, DASH, CARPET)
ELECTRONICS
LIGHTING
TIRES & BRAKE SYSTEMS
COOLANT SYSTEM
CHASSIS
GLASS
REGIONAL AUTOMOTIVE SUPPLIERS
AUTOMOTIVE FACILITIES
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200,000 to 700,000 + units per year
$1 - $3 Billion Investment
10 – 20 Miles of Conveyors
250+ Robots (Welding, Painting, Sealing)
$10 Million per day – Incoming Materials
250+ Acres Site Requirements
$500,000 - $1,000,000 per month Utilities
MATERIALS FLOW
• Process Must Match
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Powertrain (Engine, Transmission)
Seats
Exterior Styling (Grill, Trim, Color)
Features (Audio, Computer, RKE)
Glass
• JIT Delivery System
• Material AS/RS
• Quality Inspection
http://www.workhorsecc.com/tours/virtual.asp
ENVIRONMENTAL CONTROL
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PAINTS
VEHICLE WASH
COOLANTS
SEALANTS
GASOLINE & OIL
AIR CONDITIONING SYSTEMS
EXHAUST
ENGINE ASSEMBLY
ASSEMBLY AUTOMATION
INTERIOR ASSEMBLY FEED
TIRE ASSEMBLY FEED
CAR ASSEMBLY ROUTE
AUTOMATIC WELDING
ASSEMBLY TRACKING
VEHICLE TRACKING
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JIT System for Parts Delivery
Material Flow Must be in Order
Part Availability Must be Checked Early in Process
Vehicle Process Problems Must Consider Materials Flow
System Quality Must be Monitored Throughout Operation
Mercedes-Benz U.S. International, Inc. - Home of the MClass