weld information collection system

8/10/2019 Weld Information Collection System

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DATA COLLECTION FOR W.I.C.S. &

WELD SPOT CHECKING PROCESS STANDARDIZATION

1

WORLD COLLEGE OF TECHNOLOGY & MANAGEMENT

CHAPTER 1

MARUTI SUZUKI INDIA LIMITED PROFILE

1.1Introduction

Maruti Suzuki is one of India's leading automobile manufacturers and the market leader in

the car segment, both in terms of volume of vehicles sold and revenue earned. The Indian

government held aninitial public offering of 25% of the company in June 2003. As of May

10, 2007,Govt. of India sold its complete share to Indian financial institutions. With this,

Govt. of India no longer has stake in Maruti Udyog.

Maruti Udyog Limited (MUL) was established in February 1981, though the actual

production commenced in 1983 with the Maruti 800, based on theSuzuki Altokei car which

at the time was the only modern car available in India, its' only competitors- the Hindustan

Ambassador andPremier Padmini were both around 25 years out of date at that point. Maruti

are sold in India and various several other countries, depending upon export orders. Cars

similar to Maruti (but not manufactured by Maruti Udyog) are sold by Suzuki and

manufactured inPakistan and otherSouth Asian countries.

The company annually exports more than 50,000 cars and has an extremely large domestic

market in India selling over 730,000 cars annually. Maruti 800, till 2004, was the India's

largest selling compact car ever since it was launched in 1983. More than a million units of

this car have been sold worldwide. Currently, Maruti Alto tops the sales charts and Maruti

Swift is the largest selling in A2 segment.

Due to the large number of Maruti 800s sold in the Indian market, the term "Maruti" is

commonly used to refer to this compact car model. Till recently the term "Maruti", in popular

Indian culture, was associated to the Maruti 800 model.

Its manufacturing facilities are located at two facilities Gurgaon and Manesar, south of New

Delhi. Marutis Gurgaon facility has an installed capacity of 350,000 units per annum. The

Manesar facilities, launched in February 2007 comprise a vehicle assembly plant with a

capacity of 100,000 units per year and a Diesel Engine plant with an annual capacity of

100,000 engines and transmissions. Manesar and Gurgaon facilities have a combined

capability to produce over 700,000 units annually.
http://en.wikipedia.org/wiki/Initial_public_offeringhttp://en.wikipedia.org/wiki/May_10http://en.wikipedia.org/wiki/May_10http://en.wikipedia.org/wiki/2007http://en.wikipedia.org/wiki/Suzuki_Altohttp://en.wikipedia.org/wiki/Kei_carhttp://en.wikipedia.org/wiki/Hindustan_Ambassadorhttp://en.wikipedia.org/wiki/Hindustan_Ambassadorhttp://en.wikipedia.org/wiki/Premier_Padminihttp://en.wikipedia.org/wiki/Pakistanhttp://en.wikipedia.org/wiki/South_Asiahttp://en.wikipedia.org/wiki/Maruti_800http://en.wikipedia.org/wiki/Maruti_Altohttp://en.wikipedia.org/wiki/Maruti_Altohttp://en.wikipedia.org/wiki/Maruti_800http://en.wikipedia.org/wiki/South_Asiahttp://en.wikipedia.org/wiki/Pakistanhttp://en.wikipedia.org/wiki/Premier_Padminihttp://en.wikipedia.org/wiki/Hindustan_Ambassadorhttp://en.wikipedia.org/wiki/Hindustan_Ambassadorhttp://en.wikipedia.org/wiki/Kei_carhttp://en.wikipedia.org/wiki/Suzuki_Altohttp://en.wikipedia.org/wiki/2007http://en.wikipedia.org/wiki/May_10http://en.wikipedia.org/wiki/May_10http://en.wikipedia.org/wiki/Initial_public_offering


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1.4 COMPANY MISSION

A leader in the Indian Automobile Industry.

Creating Customer Delight and Shareholders wealth.

A pride of India!

1.5 LEADERSHIP

By Market share and brand equity

By operational practices

By people strategy

1.6 CUSTOMER DELIGHT

Values for money

Quality

Service

1.7 SHARE HOLDERS WEALTH

High Profitability & Image

1.8 A PRIDE OF INDIA

As a corporate citizen

Products

People

Practices

Customers


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1.11 QUALITY TOOLS

5S

SEIRI PROPER SELECTION

SEITIONARRANGEMENT

SEISOCLEANING

SEIKETSOCLEANLINESS

SHITSUKEDISCIPLINE

4M

MAN

MACHINE

MATERIAL

METHODS

3M

MURIINCONVENIENCE

MUDAWASTAGE

MURAINCONSISTENCY

3G

GENCHIGO TO ACTUAL PLACE

GENBUTSU SEE THE ACTUAL THING

GENJITSUTAKE APPROPRIATE ACTION


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1.12 The hierarchy diagram of MSIL


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1.13DIVISIONS AND DEPARTMENTS

Corporate Services Division

Legal & Secretarial Department

Corporate Communication Cell

Protocol

Strategic Initiative Group

Recruitment & Management Compensation

Human Resource Division

Employee Relations Department

Establishment & Time Office

Factory Administration Department

Organizational Development Department

Production Engineering

Production Engineering Division

Production Service Division

Engineering Directorate

QAIN Division

Service Division

Service- 1-5

MSS(D)

Parts Inspection Division

Engineering Division


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Supply Chain division

Supply Chain- 1,2,3 Division

Shipping & transport Department

Imports Department

Consumables Department

Information Technology Division

Application Group1 (AG1)



Information Technology Strategies(ITS)

IT Operation and Services(ITOS)

Marketing & Sales Secretariat

Marketing Strategy & Development

Marketing

Sales

Exports

Web-IT, E-Commerce

Spare Parts Division

Spare Parts Procurement

Warehousing & Dispatch

Spare Parts Sales

Accessories


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Vigilance Division

Security Wing

Vigilance Wing

Finance Division

Budget, Cost & Accounts Department Income Accounting

Production Division of Maruti Suzuki India Limited

Production Division in Maruti Suzuki India Limited has been renamed as Production

Business Vertical (PBV) after inclusion of Projects, Production Engineering, Vehicle

Inspection & Supplier Quality Assurance divisions in it.

Major components of PBV

Press Shop and Blanking Line

Weld Shop (1,2 & 3)

Paint Shop (1,2,& 3)

Engine Assembly (1,2,& 3)

Assembly Shop (1,2,& 3)

Machine Shop (1,2,& 3)

MaterialsX (1,2,& 3)

Plant maintenance

KB Casting

KB Engine

KB Machine Shop Production facility at Manesar Plant

SQA (Supplier Quality Assurance)

Production Engineering & Projects

Vehicle Inspection (VI)


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1.14 LAYOUT OF PROCESS FLOW

Fig. 1.2- Process flow of Maruti Suzuki India Limited


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1.15 INTRODUCTION TO VARIOUS MODELS

PRODUCT RANGE

MODELS SPECIFICATIONS YEAR OF LAUNCH

MARUTI 800 (FIRST

MODEL)796CC, HATCHBACK DECEMBER 1983

OMNI 796CC, MUV NOVEMBER 1984

GYPSY 992CC, 4WD DECEMBER 1985

MARUTI 800 (MODIFIED) 796CC, HATCHBACK APRIL 1986

MARUTI 1000 996CC, SEDAN OCTOBER 1990

ZEN 996CC, HATCHBACK OCTOBER 1993

ESTEEM 1.3L LX 1296CC, SEDAN NOVEMBER 994

ESTEEM 1.3L VX 1296CC, SEDAN NOVEMBER1995

ESTEEM 1.3L AX 1296CC, SEDAN JUNE 1996

ZEN AX (AUTOMATIC) 996CC, HATCHBACK OCTOBER 1996

GYPSY KING 1296CC, 4WD NOVEMBER1996

OMNI (E) 796CC, MUV DECEMBER 1996

GYPSY (E) 1296CC, 4WD DECEMBER 1996

MARUTI 800 (NEW

MODEL)796CC, HATCHBACK SEPTEMBER 997

ESTEEM 98 1296CC, SEDAN OCTOBER 1997

NEWOMNI&OMNI-E 796CC, MUV FEBRUARY 1998

ZEN VX & ZEN VX

AUTOMATIC

996CC, HATCHBACK

JULY 1998


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ZEN D 1200CC, HATCHBACK AUGUST 1998

MARUTI 800 EX 796CC, HATCHBACK JANUARY 1999

ZEN LX 996CC, HATCHBACK JANUARY 1999

ZEN CLASSIC 996CC, HATCHBACK AUGUST 1999

ZEN VXI 996CC, HATCHBACK OCTOBER 1999

OMNI XL 796CC, MUV OCTOBER 1999

BALENO 1586CC, SEDAN DECEMBER 1999

WAGON R 1096CC, HATCHBACK JANUARY 2000

ALTURA1586CC, HATCHBACK

(BALENO)MARCH 2000

ALTO LX, LXI 796CC, HATCHBACK SEPTEMBER 000

VERSA 1296CC, MUV DECEMBER 2001

SWIFT 1296CC, HATCHBACK MAY 2005

ZEN ESTILO 1096CC, HATCHBACK DECEMBER 2006

SWIFT DIESEL 1296CC, HATCHBACK FEBRUARY 2007

SWIFT DIESEL FEBRUARY 2007

GRAND VITARA MARCH 2007

SX4 1.600CC MAY 2007

SWIFT DZIRE MARCH 2008

A- STAR NOVEMBER 2008

RITZ MAY 2009

STINGRAY OCTOBER 2013

CELLARIO MARCH 2014


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1.16 MILESTONES

1981

Maruti Udyog Ltd. was incorporated.

1982 Stepped into a JV with SMC of Japan.

1983 Maruti 800, a 796 cc hatchback, India's first affordable car was

produced.

1984 Installed capacity reached 40,000 units. Omni, a 796 cc MUV

was in production.

1985 Launch of Maruti Gypsy (970cc, 4WD off-road vehicle).

1986 Produced 100,000 vehicles (cumulative production).

1987 Exported first lot of 500 cars to Hungary.

1988 Installed capacity increased to 100,000 units.

1992 SMC increases its stake to 50 per cent.

1994 Produced the 1 millionth vehicle since the commencement of

production.

1995 Second plant launched, the installed capacity reached 200,000

units.

1996 Launch of 24-hour emergency on-road vehicle service.

1997 Produced the 2 millionth vehicle since the commencement of

production.

1998 Launch of website as part of CRM initiatives.

1999

Launch of Maruti - Suzuki innovative traffic beat in Delhi and

Chennai as social initiatives.


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2000 IDTR (Institute of Driving Training and Research) launched

jointly with Delhi government to promote safe driving habits.

2001 Launch of customer information centres in Hyderabad,

Bangalore, and Chennai.

2002

SMC increases its stake to 54.2 per cent.

Launch of Maruti Finance with 10 finance companies in Mumbai.

Start of Maruti True value in Mumbai.

2003

Production of 4 millionth vehicle.

Listed on BSE and NSE after a public issue oversubscribed 10 times.

2004

Maruti closed the financial year 2003-04 with an annual sale of

472122 units, the highest ever since the company began

operations 20 years ago.

2005. The fiftieth lakh car rolls out in April, 2005.

2006. Maruti tops jd power csi survey for record seventh time in a row

2007

Govt of India awarded O SUZUKI with coveted padma bhusan

Board of directors give approval to new name MUL to become

maruti Suzuki India limited.

2008.

M-800 crosses 25 lakh mark

MSIL celebrates SILVER JUBILEE

MSIL launches national road safety program.

2009

Capacity to manufacture expanded from 800,000 to a million

units(Gurgaon plus Manesar) annually

All India engineering export promotion council (EEPC) award.

MSIL achieved highest sales ever in Dec2009


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CHAPTER 2

MANUFACTURING PROCESS AT M.S.I.L.

2.1 Blank

Coils are fed to blanking line & continuous supply of sheet to cutting dies result in

shaping of coils to plan blanks.

Blanks are cut by stamping or shearing process & are stacked one by one to form

large mass of blanks

These stacks of blanks are further sent to press machines for forming into shape of

body panels

Fig. 2.1 Stack of blanks


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Panel

Blanks are supplied to press lines for pressing. Blanks are converted to body panels by

this process. Panels are stored in pallets which are supplied to Weld Shops for making

White Bodies.

FIG. 2.2- Panel

Panels re

stacked in

pallet

trolleys


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2.2 PRESS SHOP

The press shop can be regarded as the starting point of the car manufacturing process.

Centrally located between weld 1, weld 2 and weld 3 supplies components to all the three

plants. The press shop has a batch production system whereas the plants have a line

production system. The press shop maintains an inventory of at least two days. The weld

shop as per the requirements picks the finished body parts from the press shop. These may be

divided as A, B and C. A components are large outer components as forexample roof, door

panels etc. These components are manufactured in the press shop at Maruti due to design

secrecy and huge investment requirements. B and C components are manufactured by

joint ventures or bought from vendors.

2.2.1 Press Shop activity

1. Currently Press Shop is producing sheet metal components for 8 running models of Maruti

Suzuki and one model of GM India - Tavera

Fig. 2.3. Press shop activities

2. The Blanking and stamping shop processes 10000 metric ton of steel / month i.e. 400 tons

a day

SStteeeellccooiill BBllaannkk PPaanneell


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2.2.2 Machine Used

Five Transfer Press (4000 ton , 3500 ton , 2400 ton -1 2000 ton -2, in terms of total

capacity i.e. (draw+trim+pierce+bend+restrike) &1 Tandem line(1500 ton draw capacity)

Two Coil processing lines (ROSLShear line & Blanking line) SPM of 60

Capacity of 55,000 strokes / day from 400 tons of steel coils

Fig. 2.4. Press machine

2.2.3 SMED: Single Minute Exchange of Dies new concept being adopted . This concept

helps in changing of die set up within single digit minute (below 9 minutes). This helps us in

improving machine utilization & operating efficiency. Since press machines are very high

cost investment & any idle time lost due to die exchange will be a cost to company.

4000 Ton

transferpress

Pressed panels

come out from

this side


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Upper die

Fig. 2.5. SMED

2.2.4 Yieldimprovement:-(Ratio of output panel to input coil in weight) is Best amongst the

SMC group Companies. ( Presently at 63.2% )

Modifications to improve yield are continuously done & till Oct-09 Press Shop has saved Rs.

7.786 millions of material in current year

Lower die

46.2

56.94

50.12

105

29.6

13.0 21

.0

77.86

0

20

40

60

80

100

120

Apr 09 May 09 Jun 09 Jul 09 Aug 09 Sep 09 Oct 09 Nov 09 Dec 09 Jan 10 Feb 10 Mar 10 Target

(09-10)

LACS

Yield Improvement


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Yield is improved by

1. Reducing the blank size

2. Utilization of scrap for making smaller sheet metal parts.

2.3 WELD SHOP

The body panels produced in the press shop and the other small components are joined here

to give the white body or shell. In a typical car body 1400 different components are

welded together. The weld shops have the following facilities.

Welding jigs

Spot welding guns

Kawasaki welding robots

Hemming machines

Punching machines

PROCESS OUTLINE:The shop has different lines for different models, each of, which isfurther divided into three parts:

UNDER BODY:Here different underbody panels are welded together. These comprise of

rear underbody, central underbody, and front engine room panel. These underbodies are put

on the conveyor and welded together to give the underbody.

MAIN BODY: As the body moves on, the conveyor roof and side body panels (prepared on

the sub lines) are welded to it to give the main body. The chassis number is punched on the

cowl top and it is welded to the front engine room panel.

WHITE BODY:The doors, hood and back door are attached on the main body with the help

of bolts and screws to make it a white body. The body is checked for dent, burr and spatter

and these defects are repaired. After inspection and repairs the body is called WBOK. It is

sent to the paint shop thereafter.


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2.4.1 PRE TREATMENT

Before sending vehicle to painting process pretreatment is done to check the quality of

paint.

Fig. 2.6. Pre- treatment procedure

2.4.2 ED PAINTING

ED is electro deposition. Vehicle is dipped in the ED solution. In this around 300V is passed

to make paint to be attached. ED is 17% of paint rest is water and some additives (EDD, M).

PROCESS

The whole solution of ED acts as electrolytic solution. Vehicle before coming to ED dip, it

undergoes pre treatment. In that phosphating is done, in which Zn phosphate is made to

attach vehicle body which help in electro deposition, in this, vehicle acts as cathode and paint

as positive ions. When current is passed paint will be attracted by vehicle till its thickness

will be covered. ED is very accurate to apply. This is about whole process. Rinsing is done

Hot water rinse Spray degreasing Dip de

WR I

WR VIWR VWR IV

WR III WR IISURFACE CONTROL

PHOSPHATING WR VII

DI WATER MISTED PROCESS

WBS


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after to remove excessive color. In rinsing industrial water is used which will not be left go

waste. That will be filtered and used again.

Fig. 2.7. ED Coating procedure

2.4.3 ULTRA FILTRATION

Ultra filtration is the process in which all the rinse pipes and dip tanks will be filtered and

cleaned, by this way water is recycled. Here Osmosis process is used to filter water.

2.4.4 IC painting

IC is intermediate coating in which 3 colors are used. They are white, blue and red. Outside

portion of vehicle is painted by robots and inside is done manually. Paint thickness is taken

care, after that vehicle is sent to IC oven. Oven temperature is 198+/-5C.

2.4.5 TOP COAT Painting

Top coating is done after checking in Dry sanding II. There are 2 sub coatings Base coat and

Clear coat. Here 11 colors are used; 8 metallic and 3 solid. Only metallic colors are coated

with clear coating. Here also outside portion of vehicle is painted by robots and inside is done

manually.

Next vehicle will move to final inspection and will be sent to assembly.

ED DIPWR I WR II

WR IV WR III RINSING BY DIPPING

OVENWR V DI WATER


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DRY SANDING

Following repairs are done:

1. Roof sanding

2. Side repair if any.

Following checking is done:

1. Dosing mark

2. Sanding mark

SOL SEALING LINE

Sealer appearance is given the preference.

3 types of guns are used.

1. Pencil gun

2. Flat gun

3. Blind gun

4. Moti gun

In this line followings are checked;

1. Powder dust

2. Extra sealer

3. Extra sealer

4. Pin hole in lamp area

5. Sealer appearance

2.5 ASSEMBLY SHOP

In the assembly shop the body is loaded on an overhead conveyor. As the conveyor moves

the body, fitments are made at various stations. There are three Assembly Shops named

ASSY-1, ASSY-2 and ASSY-3. Plant 2 and Plant 3 have similar setup but in Plant-1 there are

separate assembly lines for separate models. The assembly shop has a continuous production

system. The assembly line can be subdivided into the followings: -


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(a) Trim line

The vehicle proceeds through a series of Trim workstations where team members begin by

installing weather stripping, moldings and pads. Then they put in wiring, vents and lights.

After an instrument panel, windows, steering column and bumper supports are added, it starts

to look less like a shell and more like a car.

(b)Chassis Line

This is where many safety-related items are installed. Things like brake lines, torque, gas

tanks and power steering are double-checked. The engine is installed, along with the starter

and alternator. Then come suspension and exhaust systems. Then wheel is mounted with the

help of wheel nut fastening machine.

(c) Final Line

From there the vehicle enters Final 1, which covers many interior items such as the console,

seats, carpet, glove box and steering wheel. This is also where bumpers, tires and the battery

are added, as well as finishing touches like covers and vents. Then, Coolant, Brake oil, Power

steering oil are filled and also the A/C gas are charged.

Features

Different assembly shop layouts are followed to reduce material handling operations & to

facilitate material flow between workstations.

a) Straight-line layout Car & omni line (Assy shop-1): Simplest layout in which

material enters at 1 end & leaves at the other end.

b) U shape layout Assy shop 2 & 3: Receiving & shipping ends of line are at same

end of plant, due to material handling considerations (same forklift for both needs) or

external needs.

c) S shape layout Esteem line (AS-1): Serpentine layout to fit longer assy line in

square shop.

Separate door Assy line: - Doors are taken out from the vehicle at the first station of the trim

line. Doors fitted in the final line make working easier.


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2.6 OTHER SHOPS/DEPARTMENTS

MACHINE SHOP

The machine shop is the source of all major components for the engine assembly shop. The

un-machined crankshaft and camshaft forgings, transmission case cylinder head and cylinder

block castings are brought in the form of raw materials from the vendors. The cylinder heads

and transmission case are aluminum castings while crankshaft and camshaft are steel

forgings.

It has the following lines:

(a) Transmission case line

(b) Cylinder head line

(c) Cylinder block line

(d) Crankshaft line

(e) Camshaft line.

ENGINE ASSEMBLY

There are four types of engines which are assembled in the Engine Plant

1. FC EngineEngine with cast iron block

a. M-800

b. Omni

c. Altod. Wagon-R

e. Zen Estillo

2. Aluminium EngineEngine with aluminium block

a. Gypsy

b. SX4

c. Swift (Petrol)

d. Dezire (Petrol)


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3. KB Engine (New series of engines with aluminium block)

a. A-Star

b. Ritz

4. Diesel Engine

a. Swift (Diesel)

b. Dezire (Diesel)

c. Ritz (Diesel)


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3.3 NG Welding Flow

NG welding flow occurs at a point where the robot is not able to weld the spot correctly i.e.

the weld does not took properly due to following reasons:-

a) Spatter control

b) Spot Miss

c) Gun alignment NG

d) Tip / Tip Dressing NG

e) Half spot

f) Spot out of position

g) Gun shunting

h) Part deformation (part mismatch)

3.4 W.I.C.S. FUNCTIONALITY

Prevents NG Welding Flow

Accurate Detection of Faults

a) Spatter control

b) Spot Miss

c) Gun alignment NG

d) Tip / Tip Dressing NG

e) Half spot

f) Spot out of position

g) Gun shunting

h) Part deformation (part mismatch)

Analysis of every weld spot

Storage of weld spot parameters (upto 10 years)


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3.5 SYSTEM CONFIGURATION

Fig. 3.1. System configuration of W.I.CS.


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3.6 W.I.C.S. METHODOLOGY

The methodology on which W.I.C.S. depends is to study about the resistance waves as the

reason for the spot failure could be known by this methodology.

RESISTANCE WAVES

Resistance waves are the graphical representation between resistance values and the weld

time to show that the nugget formed is absolutely correct.

Fig. 3.2. Principle of Resistance Waves

As we can see from the above figure 3.2, the resistance value first decreases but as the temp.

of base metal is raised the resistance value climb up and form a nugget and as the nugget

expansion takes place with the increase in electrical path, the resistance value again decline.


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From the above fig. 3.3, we can clearly see that the nugget formation takes place at any other

position than required.

2. Fault due to bend parts.

Fig. 3.4. Fault seen due to bend parts

From the above fig. 3.4, we can clearly see that the nugget formation does not took place

correctly as the parts in which the spot was to be applied was bent.


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3. Fault due to get out of position.

Fig. 3.5. Fault due to get out of position seen

From the above fig. 3.5, we can clearly see that the nugget formation was formed slightly

side from its position due to which spot was not formed as required.


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-Timers output E85, when weldpoints more than thresholds of a warning level occurred

frequently in res. decrease width or aver. res.

-Reset possible in reset box

E80 High Resistance

Faults occur due to dust between the tip, power cable break etc.

Fig. 3.7. Fault of E80 high resistance waves

-Timers output E80 when it detect resistance value ahead of a threshold of high resistance

and it doesnt send weld current according to the setting value.

-Discontinue the power supply at the detection of the fault

- Measures are the basically same as low current fault.

- We can reset the fault at a reset box, but it occurs again till the fault state is removed


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GRAPHICAL REPRESENTATION OF RESISTANCE WAVES

Fig. 3.8, shows the graphical representation of resistance values at the time of welding.

Fig. 3.8. Graphical representation of resistance values

This representation shows us the difference in the resistance decreasing width. This is shown

by the line arrays of red, yellow and blue colour in above fig.


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3.6.4 METHOD FOR OBSERVING RESISTANCE WAVEFORM

To measure the transition of resistance value in every 0.5 cycle in welding, we have to

calculate the parameter 1 to 4 and supervise them. The parameter to be calculated are as

follows:-

1. Resistance width decrease: - Max. resistance valuefinal resistance value

2. Average resistance value:- Average of resistance value between 2.5cyc and weld time

(setting time) -0.5cyc

3. 3.Max resistance value:- Max value between setting time and weld time (setting time)

-1.5cyc

4. Final resistance value:- Resistance Value of weld time (setting time) -0.5cyc

Fig. 3.9 Resistance waveform


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3.6.5 SETTING OF RESISTANCE LIMIT

Resistance limits refers us to a position after which alarm would rang. Resistance limits are

classified in two levels: -

1. Alarm Level: - When the nugget formation does not take properly, limit of alarm level

is reached and the alarm rang so that the worker or engineer could take the counter

measure.

2. Fault level: - When the engineer or worker does not take counter measure after the

alarm, then the line would automatically spot.

3.6.6 PROBLEMS OCCURING IN OBSERVATION

There is a case when there is not a change of resistance. In this case, only the thin

sheet side is weld NG on sheet combination such as thin- thick-thick sheets and in the

case of sheet combination of thin-thin sheets. Therefore, there is the case that NG

points cannot stop.

Whether fault stops or not depend on a limit setting. Misjudgment occur a lot of times,

when limit setting is too rigorous. But it cannot detect weld NG, when limit setting is too

indulgent.

Now, we set limits from average and unevenness of the present data which WICS systemcollect.


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3.7 SYSTEM SUMMARY

It gives the whole functioning of W.I.C.S.

Fig. 3.10. System Summmary


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3.7 FORMAT

Fig. 3.11. Format of W.I.C.S.


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3.9 DATA REFERENCE MENU

Collection serverData reference destination of the body which does not pass M/B as of

5:00 before three days.

Offer serverData reference destination of the body which passed a M/B as of 5:00 before

three days.

Wave form of one weld ID:

-It displays wave form of resistance and current value of optional weld point on same graph.

-When I search it by a robot and a body unit, I use it

Fig. 3.12. DATA REFERNCE MENU VERSION

Wave form of each weld ID and transition:

-It displays a wave pattern of resistance value or current value of a optional weld ID on the

same graph.

-It displays transition such as resistance decrease width, an average resistance value in a

designated period for a optional weld ID.


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Judgment of all weld ID

It displays a judgment (OK, NG, dust) for weld ID of a optional body with a table.

Specified weld ID wave form monitor:

-It is always (It update it by a period for about 50 seconds) displayed the latest wave pattern

of a optional model and weld ID.

3.10 CONCLUSIONS OF W.I.C.S.

1. Customer Satisfaction: - The main motive of implementing W.I.C.S. in the YL8 line is to

provide satisfaction to the customer. As the satisfaction of customer would increase, he/

she would increase their faith on the company as a result more customers would come to

buy the car.

2. Best Quality:- the implementation of W.I.C.S. increases the quality of the car as a result

the people would be assure that this company cannot make bad products as they are

perfect in their quality.


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CHAPTER 4


4.1 Maruti Operation Standard Inspection

MOS I is known as Maruti Operation Standard Inspection sheet in which a list of all the spots

are made and their robots are mentioned which apply these spots. Cycles are divided

according to the application of spots. This sheet has a full spot detail of a car and the copy of

every sheet is listed in the file on the line so that any engineer could go on the line and with

this sheet could know about the inspection of this spot. The sheet is divided according to

main body, main body pit, white body, cowl box, etc. and their cycles.

4.2 DESCRIPTION OF MOS I

The first thing that an engineer should know in welding department is the layout of

department.

He should know that which robot is working on which car.

He should know which spots can be checked and which cannot be checked.

He should know how many men are needed for checking the spots in a given

component.

For this, MOS I has been made so that the engineer have a list of all the spots being

implemented on the components of the car.


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4.3 OBJECTIVES OF MOS I

1. To mark the spots with different colours of different robots working on the

component.

2. To mark the G.A. spots and Maru - A spots of the component.

3. To mark the cycle so that we could know how many men are needed for checking the

spots? No. of cycles is equal to no. of men needed to check the spots.

4. To know how many robots are doing welding in a given component and how manyspots are there in the given component.

4.4 METHODOLOGY ADOPTED

A MOS I sheet was made in which the picture of component with the spots was

printed.

The robots which are applying those spots in a given component were noted down

along with their spots.

Maru- A spots and G.A. spots were seen and marked on it.

The men working on a given component to check the spots were noted and cycles

were made according to their work.


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4.5CONCLUSIONS

Easy for engineer to find the robot.

Easy to find out the component details with the help of index.

To know how much labour required for checking the spots.

weld information collection system

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