1 INTRODUCTION HYUNDAIMOTORINDIALIMITED Hyundai motors has been selling cars in use since 1986, it started its heavy trucks stateside in 1988, South Korea¶s No.1 car maker. Hyundai produces various models of cars, SUVs and minivans, as well as trucks ,buses and other commercial vehicles .the company re- established itself as Korea¶s leading car maker in 1988.The company is also manufacturing machine tools for factory automation and material handling. Hyundai Motor India Limited (HMIL) is wholly subsidiary of Hyundai motorcompany, South Korea and is the 2 nd largest, f astest growing cars manufacturer in India. HMIL is si tuated in Irrungatukottai at Sri Perumbadur i n Kanchipuram dis trict in Tamil Nadu. It presently manufacturers many variants of passengers¶ cars namely SantroGetzAccent Sonata emberaTucson i10
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Hyundai motors has been selling cars in use since 1986, it started its heavy trucks
stateside in 1988, South Korea¶s No.1 car maker. Hyundai produces various models of cars,SUVs and minivans, as well as trucks ,buses and other commercial vehicles .the company re-
established itself as Korea¶s leading car maker in 1988.The company is also manufacturing
machine tools for factory automation and material handling.
Hyundai Motor India Limited (HMIL) is wholly subsidiary of Hyundai motor
company, South Korea and is the 2nd largest, fastest growing cars manufacturer in India. HMIL
is situated in Irrungatukottai at Sri Perumbadur in Kanchipuram district in Tamil Nadu. It
presently manufacturers many variants of passengers¶ cars namely
and Asia. It has been the number one exporter of passenger car of the country for the 6th
year in
a row.
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. In continuation
of its commitment to provide the Indian customer with global technology, HMIL commissionedits 2
ndplant in Feb¶2008, which produces an additional 300,000 units per annum, raising HMIL¶s
total production capacity to 600,000 units per annum. HMIL has invested to expand capacity in
line with its positioning as HMC¶s global export hub for compact cars. Apart from the
expansion of production capacity, HMIL currently has 286 strong dealer network and 540 strong
service points across India, which will be further bolstered in 2011.
In December 2008, HMIL launched the much awaited premium compact the i20
after it had a global preview at the Paris Motor show in October, 2008. In 2009 HMIL also
launched the new facelift Sonata Transform and the new Verna which is vastly improved models
compared to outgoing models. In March, 2009 Hyundai i10 clocked the fastest 300,000 salessince its launch in October, 2007. HMIL also became the only car manufacturer to introduce
automatic transmission across the segments with the launch of i20 1.2L. Petrol automatic. The
i20 also simultaneously got a powerful 1.4L CRDI engine in July, 2009. The i20 achieved the
highest safety rating by the European NCAP. In September, 2009 HMIL introduced the new
refurbished Santro with luxurious interiors and improved exterior features. The Santro has been
the highest selling model for Hyundai with more than 15 lakh units sold since its launch in India
in 1998. Hyundai Motor India in December 2009 also crossed the 25 lakh car production
milestone.
The company¶s overall performance in automobile sector was recognized by themedia as it was awarded with the prestigious ³Manufacturer of the Year´ award by both UTV,
Auto car and NDTV Profit-Car and Bike in 2009.
ABOUT HMC:
Established in 1967, Hyundai Motor Co. has grown into the Hyundai-Kia
Automotive Group which was ranked as the world¶ 5th
largest automaker in 2007 and includes
over two dozen auto-related subsidiaries and affiliates. Employing over 75000 people
worldwide, Hyundai motor posted sales of USD74.9 billion in 2007 on a consolidated basis and
USD32.8 billion on a non-consolidated basis (using the average currency exchange of 929 won per US dollar). Hyundai vehicles are sold in 193 countries through some 6,000 dealerships and
Around its factory in Tamil Nadu it has been working towards the social and
economic development of the villages, assisting them in the areas of primary healthcare,
education, basic amenities and employment opportunities .As a part of its community
development projects, the company has adopted 4 villages.
TOWARDS EMPOWERMENT:
HMI pays emphasis on the education and overall development of children and
socially vulnerable groups. Besides undertaking mentoring programs for children and
youngsters from the low-income backgrounds, Hyundai has offered private financing of
educational infrastructure in remote areas, and has set up night-schools in the villages. The
company has imparted job-oriented training to unemployed youth of the village around its plants
and has provided employment to the eligible people. As a company, it believes empowerment to
meet the needs is vital than donating necessities. Education thus forms the core pillar towardsempowerment.
SAFETY OF ALL:
Hyundai is committed to road-safety and undertakes myriad initiatives ranging
from creating awareness to help implement road discipline, besides producing cars that confirm
to highest safety standards to make the Indian roads safer. HMI, in association with the Institute
of Road Traffic Education and Delhi Traffic Police, launched an innovative road safety program
called ³Hyundai Traffic Squad´, a Student Traffic Volunteers Scholarship Scheme to create roadsafety awareness and support Delhi Traffic Police in improving Traffic Management System in
Delhi.
Under the scheme, young college and university students assist the police in
traffic management for three hours during the peak traffic hours besides educating the road users.
The scheme offers monthly stipend to 100 students, who are already selected for the purpose
under the banner ³Hyundai Traffic Squad´.
The Scheme comprises Physical training and Classroom training, Traffic drills,
hand signaling and practical control of traffic at intersections are taught in the physical training
to the volunteering students. In the classroom-training program, the students are imparted
knowledge about traffic control devices, road geometric and environmental features, laws of the
road, types of road users, administering the First Aid and post-accident management etc.
Hyundai has also sponsored for the insurance cover of the students. The tasks of
the students include controlling traffic at intersections under the direct supervision of the traffic
police, organize proper parking of vehicles in crowded commercial areas, and educate
Hyundai motor India ltd. Indulges the world class technology as the input for their
process, which contributes the making of India¶s top quality cars which are carried in variousshops.
Aluminum cast shop
Engine shop
Assembly shop
Body shop
Paint shop
Plastic shop
Press shop
Transmission shop.
1. ALUMINUM CAST SHOP:
In aluminum cast shop a critical component of the engine i.e. cylinder head I is made by casting process is aluminum foundry. A basic requirement of hi-tech engine is to
manufacture defect free castings for cylinder heads. Then these components are sent to engine
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. The assembly shop is the largest shop and has been
expanded to create a separate assembly line for EFI Sonata. The car bodies, which come
from special PBS conveyor after painting are fitted with plastic, mechanical and electrical
parts from various shops. Here the assembled cars are checked and rechecked for major
assembly defects by the QC inspector. The inspection is divided into interior and exterior
inspection and the defects are being recorded in the inspection card. The defects, if any
are corrected simultaneously on the conveyor line itself. After inspection, the car goes to
the chassis line for wheel alignment and head lamp aiming. Roll and brake test, pit
inspection for defects in the chassis and the air conditioning and the emission test on
passing these tests, the car goes to the road test where they are smoothness of operation, pick up, rating and abnormal noises, shaking and steering and a host of other function is
also performed.
The car then goes to the assembly shop to undergo the shower test, to check the water
leakage. After the shower test, the vehicles enter the final line, where they are again re-inspected
for touch up defects like scratch and paint problems. The car is then signed off and parked
outside the assembly shop where the PDI delivers again check and drive away to yard for
punching Robot is used. VIN is unique for every vehicle.
JIG:
It is plate or metal box, structure or a device usually made of metal over which
parts can be loaded and held in identical position for doing specific operation. It is mainly usedin mass production of single flow piece companies like automobile companies.
Various types of jigs are used in body shop such as:
welding assembly jig.
Installation assembly jig.
Sealant assembly jig.
Machining jig.
Swing type jig.
FIXTURE:
It is a structure which holds and locate work piece in a desired and definite position for a
specific purpose like inspection, marketing etc. Various types of Fixtures are used in body shop
such as,
Checking fixture.
Inspection fixture.
Aperture fixture.
In a body mainly two types welding are used such as spot welding and MIG welding.
VARIOUS LINES IN BODY SHOP:
DOOR LINE:
Here inner (LP) and outer (MIP) panels for doors are joined and sent in same
The various moving parts like Doors, Hood, Tail gate, Door hinge, Fender are
assembled to the body manually using fasteners and jigs.
BODY COMPLETE LINE (BC2) ± SLAT LINE:
The final operations, touchup and inspection of the completed BIW are done here.
The bodies are discontinued from the line sent to rework area if any correction/repairs are
needed. The bodies passed from BC2 and rework area are then sent to the ³paint shop´.
CO2 WELDING:
This type of welding is done manually where the parts to be welded are not
accessible to the robots.
Special features:
y Good mechanical properties of Welding Metal
y No Porosity,
y Little tendency to over cut,
y Sound Weld deposition with consistency.
Application:
y Used for Carbon and Low Alloy Steel from 1.2mm to 8mm and above,
y Fabrication of Structural Steel,
y In semi automatic and automatic process to increase yield, productivity and quality,y Mining Industries, Automobile Industries, Chemical Plant commissioning and erection,
Ship building, Boilers and pressure vessels, etc.
Technical specification
The wire rods used for making co2 wire are ER7086, WR3M, and WR3. The wires are made as
per IS6419 standard
Used for welding consumable wires in grades of high-strength steel structures like vehicles,
building, boat, bridge and etc, these can also be used for speed welding of sheet and pipes. These
are available at industry leading prices to our clients.
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 in-house. In engine shop
the main components viz. Cylinder head, Crank shaft, Cam shaft and Connecting rod which need
precision dimensional accuracy, are machined using special purpose machines. Each componentis machined in a separate line. Thus there are 5 different lines in E1machining line and 4 in E2
machining line (As cam shaft is machined in E1 line only). Cylinder head is made by die casting
process in Aluminum foundry. Basic requirement of High-tech Engine is to manufacture defect
free casting for cylinder head. After this the machined parts of the cylinder head are sent to the
sub assembly, where they are assembled. Following this all the parts are sent to the main
assembly. The detail report of the machining of each component is shown.
Details of kappa engine of Hyundai
KAPPA ENGINE
The facts first: the new engine is an all-aluminum, DOHC, 16-valve unit that produces
80bhp@5200rpm, 11.4kgm@4000rpm, and is redlined at 6500rpm. It has a lubricated timing
chain, offset crank, and spark plugs that have been lengthened from 19mm to 26.5mm. The
valves incorporate hydraulic lash adjustors. Other innovations include the lack of a fuel return
line that helps save fuel by eliminating evaporation, and fuel injectors whose pulsing can be
varied, depending on the requirements of the moment ³warming up, power, or normal driving.
The i10 automatic will also be available with a four-speed transmission.
The cylinder block forms the basis framework of the engine. It houses the engine
cylinders which serve as bearings and guides, for the pistons reciprocating in them. Around the
cylinders there are passages for the circulation of coolant. Cylinder block also carries lubrication
oil to various components through drill passages called µoil galleries¶. During manufacturing, the
oil holes are drilled and rarely cast. Here, cast iron is used to cast the cylinder block, in this
carbon is present as flakes of graphite, which makes it, more wear and corrosion resistant apart
from its better mach inability. Advantages of cast iron over Aluminum alloys are;
y It is good foundry material.
y It has high mach inability.
y It does not wrap, under high temperatures and pressures, developed in the cylinders.
y Due to its slightly porous nature, it remains better the lubricating oil film.
y It has good sound damping properties.
y It has low value for the coefficient of thermal expansion.
y It is relatively cheap
CYLINDER HEAD
The cylinder head accommodates the valve guides, camshaft and the valves. The cylinder
head is manufactured by the casting process in aluminum foundry plant of the company.
Aluminum being a light metal and easily cast able one. It is used for cylinder head casting. The
cylinder is of two types: Distributor less ignition type (DLI) and distribution ignition type (DI).
The distributor refers to the device used by ignition system to deliver spark to cylinders
according spark timing of each cylinder. In case of distributor less ignition type, it uses a cam
sensor (CPS) to detect the position of valves and accordingly induce spark in the cylinders. The
CPS is a new concept that uses electronic method of spark ignition and it is more reliable at all
speeds of the engine. There are provisions for two inlet valves and one exhaust valves for each
cylinder, which are 4 in number. There are also 10 bolt holes. 11 water jacket holes and 3 oil
drain holes in a cylinder block. The various stages of machining are shown:
CONNECTING ROD
The connecting rod so used to connect the crankshaft to the piston head of the cylinder. The
connecting rod transforms the reciprocating motion of the piston to the rotary motion of thecrank shaft. From the crank shaft it is transmitted to the transmission assembly from which it is
transferred to the wheels of the vehicle. The connecting rod is machined in two separate parts for
easy machining and assembly in crankshaft. Then they are fitted by nuts and bolts and are sent to
engine assembly line. The raw material is imported from KORIA.
21. Rocker arm cover is fixed. This cover has opening through which the oil can be poured. Here
the camshaft sensor is fixed.
22. Next they fix the alternator brace where the alternator is mounted.
23. Then they fix the inlet manifold. A throttle body is fixed through which the air enters insidethe manifold. This inlet manifold has a throttle body sensor, which is connected to the ECU. The
manifold carries ISCA (Ideal Speed Control Accelerator), which controls the air fuel mixture at
ideal position. This ISCA and injector are called as actuators.
24. Next they fix the oil filter, spark plug (4 No¶s), and casing cover, it absorbs heat and directs
outside.
25. Then they fix water inlet pipe.
26. Spark plug cable is fixed which is connected to the ignition coil. This coil gets power from
the battery.
27. Vacuum nipple is also fitted which absorbs the extra air in the brake booster.
28. The manifold stay is fitted, which holds the engine head and block in order to avoid
vibration.
29. The alternator is fitted that converts the mechanical energy to electrical energy.
30. Crank sensor wheel is fixed. This shows the position of the stroke
31. Rear plate is fixed, this plate act as a washer for fitting the starter mortar.
32. Flywheel is fixed for engine balance power transmission.
33. Water temperature controller is fixed it has 2 functions:-
y It takes hot water from the engine and sends it to the radiator for cooling
y It sends 80ºC water into water inlet pipe.
34. Flywheel has holes to fit for level pin to fit clutch plate. Then they fix the timing cover.
35. Next they fix the ignition coil which carries 12V current from the battery and this current is
converted to 25KV-35KV.
36. Next they fix the crank pulley (the crank pulley is connected to the alternator by means of
belt) as the belt rotates the alternator also rotates and current is generated.
37. Next they fix the belt connecting the crank pulley. Alternator pulley, A/C, power steering and
The following are the components made in transmission machining line.
y Transmission case
y Clutch housing
y Input speed gears 3/4/5
y Output speed gears 3/4/5
y Output shaft
y Input shaft
y Speed gear ½
y Speed gear 3/4/5
y Clutch gear
y Reverse idler gear
y Differential drive gear
y Synchronize sleeve 1&2,3&4,5
HEAT TREATMENT:
After all soft stage machining operations are finished the components are moved
to heat treatment to improve their material property like surface hardness and tempering.
Carburizing is followed in the heat treatment process, it is mainly done to improve its surface
hardness and wear resistance. The principle of this process is to convert the outer surface of the
job into high carbon steel by forming a solid solution of iron and carbon.
In heat treatment process the components¶ surfaces must be free from oil and dirtin order to get homogeneous property. So the components undergo washing operation initially to
clean all surfaces. After cleaning the metals move into the furnace, inside the furnace
carburizing operation is used in heat treatment process. The materials are heated up to 930°C
and RX gas is allowed to flow over the components at same temperature, in this process the
carbon particles get deposited over the component.
This operation is used to create internal splines in the sleeves.
5. ELECTRON BEAM WELDING:
electron beam welding (EBW) is a fusion welding process in which a
beam of high velocity electrons is applied to the materials being joined.
DURING HEAT TREATMENT:
The gears are heat treated to improve hardness. In heat treatment carburizing is
done in a BCF & CCF furnace to increase the hardness. Induction hardening is done when core is
to be soft and the outer surface is to be hard.
THE PROCESS FOLLOWS
1. DEGREASING:
It removes oil from the working substance by using degreasing furnace, which
heats the working substance by
LPG burner. The visual inspection is done to check that no oil or grease is
present.
2. CARBURIZING & QUENCHING:
This procedure is done to increase the hardness & wear resistance of the
substance by heating the working substance up to 930° in a batch carburizingfurnace and then quenching to salt bath. Several instruments such as Rockwell
hardness tester and Vickers hardness tester test hardness. Appropriate hardness is
58 HRC MIN.
3. WASHING MACHINE:
This machine is used to remove salt from the working substance. The substance is
dipped in hot water or given a hot water shower and then a cold water rinse. Visual
inspection is done to check for no salt deposit.
4. TEMPERING FURNACE:
Working substance is heated in a tempering furnace at 160° C and then air cooled
to remove the internal stresses. Destructive testing of a single piece inspects hardness and case
The output shaft is supported by two taper roller bearings inside the casting. The
output shaft is connected with differential unit.
DIFFERENTIAL UNIT:
The differential unit consists of sun and planet gears. These gears are
perpendicular to each other. It has two sets of sun and planet gears. As the input pinion spins, it
meshes with the ring gear. The ring gear spins, spinning the cage and the two captive pinions.
When the vehicle is travelling in straight line, drive pinion doesn¶t try to spin differently from
others, so the captive pinions don¶t spin and the turning of the ring gear is translated directly to
both drive pinions. These are connected to the drive shaft, to the wheels. So effectively the ring
gear spins the wheels at the same speed that it is turning. When the vehicle starts to turn a corner,one of the wheels is going to spin more quickly than the other. At this point, the captive pinions
come into play, allowing the torque to them. One can tell if the differential is working properly
or not by jacking the driven axle up off the ground and spinning one wheel. When this is done,
because the gearbox is stationary, it holds the ring solid, captive pinions spin in opposite
direction and the other wheel on the axle spins the other way around. This also explains why a
two wheel drive vehicle can get into trouble when one wheel has less friction with the ground
than the other. The open differential cannot compensate for this. If one drive pinion is held solid
compared to other, then all the input gears redirected to drive pinion that has the least resistance.
This is why when you turn a two wheel drive car with one wheel on ice and the other on the
road, the wheel on the ice spins and the wheel on the road doesn¶t. You don¶t go anywhere
because all the engine power is directed to the wheel with least resistance the one on the ice.
Imagine the same scenario on a four wheel drive vehicle that has open differentials on the front
and rear. If you are off-riding in such a vehicle and get it into a situation where one front wheels
are off the ground, you are stuck. The differentials will spin the airborne wheels and send no
torque to the ones on the ground.
CLUTCH HOUSING:
The above picture shows transmission case other PA, MX & LC type. This is
made of aluminum. In the transmission case there are several provisions made for the assemblingthe parts like counter weight, clutch shaft, differential unit, input shaft and output shaft and fork
lift(tag) during the course of transmission assembly line,. The clutch housing ids bolted on the
pallet over the conveyor which runs at constant a speed.
CLUTCH RELEASE FORK ASSEMBLY:
It is used to operate the clutch engage and disengage. Clutch release fork
assembly consists of return spring to bring the clutch pedal back.
COUNTERWHEIGHT:
It is the part of the clutch housing assembly which is used as control for the
clutch. The purpose of the counter weight is similar to return spring.
FORK LIFT:
The manual gearbox is shown has a series of selector forks which are moved by
the physical position of the gear stick. In a sequential box, those selector forks are connected to a