The Automotive Body Manufacturing Systems and Processes

Foreword.

Acknowledgments.

List of abbreviations.

1 Introduction.

1.1 Anatomy of a Vehicle, Vehicle Functionality and Components.

1.2 Vehicle Manufacturing: An Overview.

1.3 Conclusion.

Exercises.

2 Stamping and Metal Forming Processes.

2.1 Formability Science of Automotive Sheet Panels: An Overview.

2.2 Automotive Materials.

2.3 Automotive Stamping Presses and Dies.

2.4 Tailor Welded Blanks and their Stamping.

2.5 Advances in Metal Forming.

2.6 Stampings Dimensional Approval Process.

2.7 Stamping Process Costing.

Exercises.

3 Automotive Joining.

3.1 Introduction.

3.2 Fusion Welding Operations.

3.3 Robotic Fusion-Welding Operations.

3.4 Adhesive Bonding.

3.5 Welding and Dimensional Conformance.

3.6 Advances in Automotive Welding.

3.7 The Automotive Joining Costing.

Exercises.

4 Automotive Painting.

4.1 Introduction.

4.2 Immersion Coating Processes.

4.3 Paint Curing Processes, and Balancing.

4.4 Under-Body Sealant, PVC and Wax Applications.

4.5 Painting Spray Booths Operations.

4.6 Material Handling Systems Inside the Painting Area.

4.7 Painting Robotics.

4.8 Paint Quality Measurements.

Exercises.

5 Final Assembly.

5.1 Basics of Final Assembly Operations.

5.2 Ergonomics of the Final Assembly Area.

5.3 Mechanical Fastening and Bolting.

Exercises.

6 Ecology of Automotive Manufacturing.

6.1 Introduction of Automotive Manufacturing Ecology.

6.2 Energy Consumption and Accounting.

6.3 The Automotive Materials' Ecological Impact.

6.4 The Painting Process Ecology.

6.5 Ecology of the Automobile.

7 Static Aspects of the Automotive Manufacturing Processes.

7.1 Introduction.

7.2 Layout Strategies.

7.3 Process-Oriented Layout.

7.4 Cell-Based Layout Design.

7.5 Product-Based Layout.

7.6 Lean Manufacturing Tools for Layout Design and Optimization.

7.7 Locational Strategies.

Exercises.

8 Operational Aspects of the Automotive Manufacturing Processes.

8.1 Introduction.

8.2 Aggregate Production Planning.

8.3 Master Production Scheduling (MPS).

8.4 Material Requirement Planning (MRP).

8.5 Production Line Control and Management Style.

8.6 Selection and Management of Suppliers.

8.7 An Overview of the Automotive Quality Tools.

Exercises.

References.

Index.