INDUSTRIAL VISIT REPORT

On the part of our industrial visit we visited Hyundai Motor India Limited (HMIL), Sri perumbudur, Irrungattukottai, Kanchipuram District. About Hyundai Motor India Limited(HMIL) :Hyundai Motor India Limited (HMIL) is a wholly owned subsidiary of Hyundai Motor Company (HMC), South Korea and is the largest passenger car exporter and the second largest car manufacturer in India. HMIL presently markets 7 models of passenger cars across segments. The A2 segment includes the Santro, i10 and the i20, the A3 segment includes the Accent and the Verna, the A5 segment includes the Sonata Transform and the SUV segment includes the Santa Fe. HMIL's fully integrated state-of-the-art manufacturing plant near Chennai boasts of the most advanced production, quality and testing capabilities in the country. To cater to rising demand, HMIL commissioned its second plant in February 2008, which produces an additional 300,000 units per annum, raising HMILs total production capacity to 600,000 units per annum. In continuation with its commitment to providing Indian customers with cutting-edge global technology, HMIL has set up a modern multi-million dollar research and development facility in the cyber city of Hyderabad. It aims to become a centre of excellence for automobile engineering and ensure quick turnaround time to changing consumer needs. As HMC's global export hub for compact cars, HMIL is the first automotive company in India to achieve the export of 10 lakh cars in just over a decade. HMIL currently exports cars to more than 115 countries across EU, Africa, Middle East, Latin America and Asia Pacific. It has been the number one exporter of passenger car of the country for the sixth year in a row. To support its growth and expansion plans, HMIL currently has a 329 strong dealer network and 698 strong service points across India, which will see further expansion in 2011. In our industrial visit to HMIL the R&D department of Hyundai allowed us to have a view on manufacturing process of Hyundai i10, i20 (basic) and fluidic verna

Stages In Car Manufacturing

:-

There are five stages in the manufacturing of a car. They are 1. PRESS SHOP 2. BODY SHOP 3. PAINT SHOP 4. ASSEMBLY SHOP 5. ENGINE & TRANSMISSION SHOP 1. Press shop :-

A computer controlled line that converts sheet metal to body panels with high dimensional accuracy and consistency. Thus obtained metal sheet is automated to body shop for further processing.

2. Body Shop :It is a hi-tech line that builds full body shells from panels. Automated robotic arms are used for intricate welding operations that ensure superior and consistent build quality. For developing single car body it requires 14 robotic arms. HMIL uses 186 robotic arms in its entire production unit in order to produce 2 cars per a minute. Thus manufactured body of the car is automated to Paint shop.

3. Paint shop:It is one of the most modern paint shops in the country and uses the environment friendly water based process for superior and lasting exteriors. A unique process management system followed here helps us deliver the most extensive colour range, independent of minimum batch requirements, helping customers get their preferred colour anytime. Thus painted cars body is automated to assembly shop for the assembly of various parts of car.

4. Assembly shop :In Assembly Shop all the engine and suspension parts, the electrical parts, the under body parts etc are fitted into the car. The cars go through complete testing in the Assembly Shop. The Assembly Shop comprises the Trim Line, the Chassis Line, the Final Line and the OK Line.

5. ENGINE & TRANSMISSION SHOP :One of the biggest engine shops in the country, this unit is equipped with the most modern tooling and testing facilities to make a wide range of engines inhouse. In the process of manufacturing engines and other accessories HMIL imports its raw materials from its vendors.

Hyundai Technology Chassis :We deploy cutting-edge materials and new technologies in the development of chassis parts to secure unrivalled riding comfort, driving performance and safety.

Chassis parts that have undergone advanced virtual analyses and passed numerous tests and standards deliver world-best performance.

Hyundai Research & Development - Performance & Functional Tests DIRVING CONFIDENTLY IN ANY ENVIRONMENT :-

Our wind tunnel test facility pits cars against 200km winds created by ultralarge propellers measuring 8.4m. The KRW45 billion facility is the largest of its kind in Asia. Vehicles are put through a wide range of punishing tests that recreate diverse environmental conditions such as extreme temperatures, and heavy rains and snow to ensure that they are able to deliver optimal levels of safety and durability under any circumstance, anywhere. WIND TUNNEL TEST FACILITY :The wind tunnel test evaluates the aerodynamics and aero acoustics of a vehicle. Tests are conducted to reduce wind resistance for improved fuel economy and reduced wind noise which is a major cause of noise when driving at high speeds. Key facilities include the main fan measuring 8.4m in diameter and capable of generating winds at speeds of up to 200km. In addition, an automotive electric scale can measure various forms of wind resistance encountered by vehicles during high speed driving. The sound-absorbing wall of the facility minimizes reflective noise and enables accurate measurements of noises created by the vehicle. EMC TEST CHAMBER :The electromagnetic compatibility (EMC) chamber assesses the possibility of disturbances in electromagnetic waves, induction and audio reception while driving.

ENVIRONMENTAL TEST WING :HOT CHAMBER :-

Temperatures inside the hot chamber can be raised to 20-60. The facility is used to help develop the engines cooling and A/C systems. Additionally, electronic, rubber and plastic parts are put through the heat test. COLD CHAMBER :The temperature range of the cold chamber is -40-20. This is where various low temperature functional tests of various parts are conducted that assist in the development of systems to remove frost and humidity from windows to enable safe driving. The heater performance test helps to create a comfortable indoor environment even during the coldest winter days. HEAVY SNOW/RAIN CHAMBER :This facility is capable of generating 70mm of snow and 150mm of rain per hour, thereby allowing researchers to assess the freezing of wiper systems and motor troubles due to frozen cooling fans. Various electric and electronic sensors and parts, as well as car interior and engine intake devices, are subjected to the test to locate any flaws resulting from exposure to snow or water. CONCLUSION :This industry visit enables us to enlarge our technical vision in such a way so that we can apply our subject matters into real time products. In this particular visit we understood, how cars are manufactured in HYUNDAI and how our subjects are implemented in the manufacturing process. We excited a lot and a lot when we came to know about the manufacturing process and upcoming projects of HYUNDAI. Thus our industrial visit to HYUNDAI is helpful to us in all the ways so that we can able to know about visionary behind car manufacturing process and the automation techniques involved in industry.