1、Automotive Vehicle Assembly Processes and Operations Management 6673_Book.indb 1 12/27/16 9:58 AMOther SAE books of interest: Manufacturing System and Process Development for Vehicle Assembly He (Herman) Tang (Product Code: R-457) Formula 1 Technology Peter Wright and Tony Matthews (Product Code: R-
2、230) Reliability and Maintainability Guideline for Manufacturing Machinery and Equipment (Product Code: M-110.2) Handbook of Automotive Engineering Ulrich W. Seiffert and Hans Hermann Braess (Product Code: R-312) Mechanics Modeling of Sheet Metal Forming Sing C. Tang and Jwo Pan (Product Code: R-321
3、) The Multi Material Lightweight Vehicle (MMLV) Project David Wagner, Jeff L. Conklin, Matthew Zaluzec, Timothy W. Skszek (Product Code: PT-170) Aluminum Auto-body Joining George Nicholas Bullen (Product Code: PT-173) For more information or to order a book, contact: SAE International 400 Commonweal
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5、 He (Herman) Tang Warrendale, Pennsylvania, USA 6673_Book.indb 3 12/27/16 9:58 AM400 Commonwealth Drive Warrendale, PA 15096-0001 USA E-mail: CustomerServicesae.org Phone: 877-606-7323 (inside USA and Canada) 724-776-4970 (outside USA) Fax: 724-776-0790 Copyright 2017 SAE International. All rights r
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11、at books.sae.org 6673_Book.indb 4 12/27/16 9:58 AMv Contents Preface xiii I.1 Approach . xiii I.2 Organization and Content . xiii Acknowledgement xiv Chapter 1: Automotive Industry and Competition1 1.1 Automotive Market Overview 1 1.1.1 Global Automotive Manufacturing 1 1.1.1.1 Global Market by Regi
12、on . 1 1.1.1.2 Major Automakers . 3 1.1.2 Characteristics of Automotive Market 5 1.1.3 Dimensions of Market Competition 7 1.1.3.1 Four Market Competitive Attributes . 7 1.1.3.2 Five-Force Model 9 1.1.3.3 Manufacturing Capacity . 10 1.2 Manufacturing Competition and Assessment . 11 1.2.1 Automotive I
13、ndustry Competition . 11 1.2.1.1 Quality and J.D. Power Indexes . 11 1.2.1.2 Labor Utilization Efficiency 12 1.2.2 Automaker Performance Assessment . 14 1.2.2.1 Total Company Performance . 14 1.2.2.2 Consumer Reports Magazine 15 1.2.2.3 Other Indicators 16 1.3 Business Strategy Considerations. . . .
14、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 1.3.1 Strategy Basics . 17 1.3.1.1 Three-Level Strategy 17 1.3.1.2 Generic Strategies 19 1.3.1.3 Characteristics of Strategy . 20 1.3.2 Discussion on Automakers Strategy 22 1.3.2.1 Strategies for Automakers . 22 1.3.2.2 Corporate Strategy
15、 Case Studies 23 1.3.2.3 Manufacturing Strategies 24 1.4 Exercises 26 1.4.1 Review Questions 26 6673_Book.indb 5 12/27/16 9:58 AMvi Contents 1.4.2 Research Topics 27 1.5 References 28 Chapter 2: Automotive Manufacturing Operations. 31 2.1 Overall Automotive Manufacturing 31 2.1.1 Introduction to Veh
16、icle Assembly Plants . 31 2.1.2 Flows in Automotive Manufacturing 32 2.1.3 Process Flows of Vehicle Assembly . 33 2.2 V ehicle Assembly Operations 34 2.2.1 Body (Weld) Framing . 34 2.2.1.1 Overview of Vehicle Body Assembly 34 2.2.1.2 Process Flow of Body Assembly 35 2.2.2 Paint Operation 37 2.2.2.1
17、Overall Painting Flow . 37 2.2.2.2 Main Painting Processes . 38 2.2.3 General Assembly 41 2.2.3.1 Process Flow of General Assembly 41 2.2.3.2 General Assembly Operations 43 2.2.3.3 Characteristics of General Assembly 44 2.3 Automotive Part Manufacturing . 46 2.3.1 Sheet Metal Stamping . 46 2.3.1.1 O
18、verall Stamping Operation . 46 2.3.1.2 Typical Stamping Processes 46 2.3.1.3 Hydroforming Process 48 2.3.2 Powertrain Manufacturing 50 2.4 Distinctiveness of Automotive Manufacturing . 53 2.4.1 System Perspective on Automotive Manufacturing . 53 2.4.1.1 Viewpoint of Conversion 53 2.4.1.2 Functional
19、Viewpoint . 54 2.4.1.3 Performance Viewpoint . 55 2.4.1.4 Subsystems of Vehicle Assembly 56 2.4.2 Characteristics of Vehicle Manufacturing 58 2.4.2.1 Types of Manufacturing Processes 58 2.4.2.2 Discussion of Vehicle Manufacturing Processes . 60 2.5 Exercises 62 2.5.1 Review Questions 62 2.5.2 Resear
20、ch Topics 62 2.6 References 62 Chapter 3: Joining Processes for Body Assembly 65 3.1 Resistance Spot Welding 65 3.1.1 RSW Principle . 65 3.1.2 Characteristics of RSW Process . 67 3.1.2.1 Process Parameters of RSW 67 6673_Book.indb 6 12/27/16 9:58 AMvii Contents 3.1.2.2 Steel and Aluminum Welding 68
21、3.1.2.3 Controls of Current and Force 70 3.1.3 RSW Equipment . 71 3.1.3.1 Weld Guns 71 3.1.3.2 Electrode Caps . 72 3.1.3.3 Correction of Cap Wear . 73 3.2 Laser Beam Welding 74 3.2.1 Principle and Characteristics of LBW. . . . . . . . . . . . . . . . . . . . . . 74 3.2.1.1 Principle of Laser Welding
22、 . 74 3.2.1.2 Characteristics of Laser Welding 75 3.2.1.3 Advantages of Laser Welding 77 3.2.2 Challenges to LBW and Solutions 78 3.2.2.1 Initial Investment . 78 3.2.2.2 Welding Zinc-Coated Steels 79 3.2.2.3 Advancements of LBW 80 3.3 Other Types of Welding . 81 3.3.1 Arc Welding . 81 3.3.1.1 Princi
23、ples of Arc Welding 81 3.3.1.2 Characteristics of Arc Welding . 83 3.3.2 Projection and Draw Arc Welding 84 3.3.2.1 Projection Stud Welding . 84 3.3.2.2 Drawn Arc Stud Welding 85 3.3.3 Friction Stir Welding 87 3.3.4 Impact Welding 89 3.4 Mechanical Joining and Bonding . 90 3.4.1 Self-Piercing Riveti
24、ng . 90 3.4.2 Clinching . 91 3.4.3 Adhesive Bonding 92 3.4.3.1 Applications of Adhesive Bonding 92 3.4.3.2 Design Considerations for Bonding Joints 93 3.4.3.3 Process Considerations for Bonding Joints . 94 3.5 Selection of Joining Processes 95 3.5.1 Advancement Trends in Joining 95 3.5.2 Overall Com
25、parison 96 3.5.3 Selection Considerations 98 3.6 Exercises 98 3.6.1 Review Questions 98 3.6.2 Research Topics 99 3.6.3 Analysis Problems 99 3.7 References . 100 Chapter 4: Vehicle Paint Processes .105 4.1 Surface Treatments and Electrocoating . 106 4.1.1 Clean and Phosphate Processes . 106 6673_Book
26、.indb 7 12/27/16 9:58 AMviii Contents 4.1.1.1 Process Flow of Phosphate 106 4.1.1.2 Process Parameters of Phosphate 109 4.1.2 Electrocoating . 110 4.1.2.1 Introduction to Electrocoat . 110 4.1.2.2 Principle of Electrodeposition 111 4.1.2.3 Process Parameters of E-Coat 113 4.1.2.4 Challenges to E-Coa
27、t 116 4.1.3 Phosphate and E-Coat Facilities 116 4.1.3.1 Vehicle Conveyance . 116 4.1.3.2 Material Feed and Filtration 117 4.1.3.3 E-Coat Anodes and Anolyte System . 118 4.2 Paint Spray Processes 120 4.2.1 Paint Materials and Pretreatment 120 4.2.1.1 Paint Materials 120 4.2.1.2 Pretreatment for Paint
28、 Process . 122 4.2.2 Primer Application 123 4.2.3 Color Coat and Clear Coat Processes . 125 4.2.4 Paint Equipment and Facilities 129 4.2.4.1 Spray Applicators . 129 4.2.4.2 Paint Booth . 131 4.3 Other Operations in Paint Shop . 133 4.3.1 Paint Cure Process . 133 4.3.1.1 Curing Process Parameters . 1
29、33 4.3.1.2 Considerations on Curing 135 4.3.1.3 Wet Process . 136 4.3.2 Nonpainting Operations . 136 4.3.2.1 Sealing Operations in Paint Shop 136 4.3.2.2 PUR Foam Applications 139 4.4 Exercises . 139 4.4.1 Review Questions . 139 4.4.2 Research Topics . 139 4.5 References . 140 Chapter 5: Production
30、Operations Management 141 5.1 Production Planning and Execution . 141 5.1.1 Production Planning Approaches 141 5.1.1.1 Aggregate Planning 141 5.1.1.2 MPS . 142 5.1.1.3 MRP and MRP II 143 5.1.1.4 ERP 143 5.1.2 Push-Based and Pull-Based Execution 145 5.1.2.1 Distinction of Push and Pull 145 5.1.2.2 Ju
31、st In Time and Inventory 147 5.1.2.3 Work in Process . 148 6673_Book.indb 8 12/27/16 9:58 AMix Contents 5.1.2.4 Characteristics of Push and Pull . 149 5.1.3 Production Control based on Customer Demands . 150 5.1.3.1 Three Types of Planning and Execution . 150 5.1.3.2 Characteristics of ATS and ATO .
32、 151 5.2 Key Performance Indicators 153 5.2.1 Manufacturing Operational Performance . 153 5.2.1.1 Basic Assessment of Performance 153 5.2.1.2 Perspective on Operational Performance. . . . . . . . . . 155 5.2.2 Production Throughput Measurement . 156 5.2.2.1 Throughput Monitoring 156 5.2.2.2 Other In
33、fluencing Factors . 158 5.2.3 Overall Equipment Effectiveness 158 5.3 Manufacturing Costs 160 5.3.1 Types of Manufacturing Costs. . . . . . . . . . . . . . . . . . . . . . . . . . . 161 5.3.1.1 Operating Costs . 161 5.3.1.2 Overhead Costs . 164 5.3.2 Economic Analysis of Equipment 164 5.3.2.1 Equipm
34、ent Depreciation 164 5.3.2.2 Depreciation of Tooling and Facilities 166 5.3.2.3 Economic Life of Equipment 167 5.4 Equipment Maintenance Management . 168 5.4.1 Equipment Maintenance Strategies 168 5.4.1.1 Types of Maintenance Management 168 5.4.1.2 Cost and Risk of Maintenance . 170 5.4.1.3 Total Pr
35、oductive Maintenance . 172 5.4.2 Maintenance Effectiveness 172 5.4.2.1 Measured by System Performance . 172 5.4.2.2 Measured by Total Cost 173 5.5 Exercises . 175 5.5.1 Review Questions . 175 5.5.2 Research Topics . 176 5.5.3 Analysis Problems . 176 5.6 References . 177 Chapter 6: Quality Management
36、 for Vehicle Assembly .179 6.1 Introduction to Vehicle Quality . 179 6.1.1 Recognition of Quality . 179 6.1.2 Design for Quality . 181 6.1.3 Manufacturing Quality Assurance . 184 6.1.3.1 Overall Considerations for Manufacturing Quality . 184 6.1.3.2 Quality Inspections and Audits 186 6.1.3.3 Total Q
37、uality Management 187 6.2 Vehicle Manufacturing Quality 188 6.2.1 Assembly Joining Quality 188 6673_Book.indb 9 12/27/16 9:58 AMx Contents 6.2.1.1 Concept of Joint Quality 188 6.2.1.2 RSW Quality Assessment . 189 6.2.1.3 Other Joint Quality Inspections 191 6.2.2 Body Paint Quality 192 6.2.3 Vehicle
38、Final Quality Audit . 195 6.2.3.1 Final Inspections of Vehicles 195 6.2.3.2 Assessment based on Final Audits . 198 6.3 Dimensional Quality Management 200 6.3.1 Metrology Review . 200 6.3.1.1 Fundamental Concepts . 200 6.3.1.2 Repeatability and Reproducibility . 201 6.3.2 Dimensional Quality Inspecti
39、ons 204 6.3.2.1 Quality Inspections in Manufacturing 204 6.3.2.2 In-Line and Offline Inspections 206 6.3.3 Functional Build in Tryouts . 208 6.4 Part Quality Management 210 6.4.1 Production Part Quality Assurance . 211 6.4.1.1 Principle of PPAP . 211 6.4.1.2 Requirements of PPAP . 213 6.4.2 Quality
40、Monitoring and Sampling . 215 6.4.2.1 Principle of Sampling Plans . 215 6.4.2.2 Discussion of Sampling Applications . 217 6.5 Exercises . 219 6.5.1 Review Questions . 219 6.5.2 Research Topics . 219 6.6 References . 220 Chapter 7: Operational Performance Improvement . 223 7.1 Performance Improvement
41、 . 223 7.1.1 Performance Continuous Improvement 223 7.1.1.1 Mindset of Continuous Improvement 223 7.1.1.2 Employee Participation . 224 7.1.2 Approaches of Continuous Improvement . 227 7.1.2.1 Problem Solving Process 227 7.1.2.2 Structured Brainstorming Approaches 230 7.1.2.2.1 Nominal group techniqu
42、e . 230 7.1.2.2.2 Affinity diagram . 231 7.1.2.2.3 Force field analysis . 232 7.1.2.2.4 5-whys . 232 7.1.3 Value Stream Analysis . 233 7.2 Production Throughput Improvement . 235 7.2.1 Production Throughput Analysis 235 7.2.1.1 Influencing Factors to Throughput . 235 7.2.1.2 Case Study of Throughput
43、 Improvement . 237 6673_Book.indb 10 12/27/16 9:58 AMxi Contents 7.2.2 Production Downtime Analysis . 239 7.2.2.1 Downtime Tracking 239 7.2.2.2 Downtime Analysis 239 7.2.2.3 Evaluation and Prioritization 241 7.2.3 Production Complexity Reduction . 242 7.2.3.1 Reduction of Vehicle Configurations . 24
44、2 7.2.3.2 Batch Processing 243 7.3 Bottleneck Analysis 244 7.3.1 Theory of Constraints 245 7.3.2 Stand Alone Availability 246 7.3.2.1 Distinction of SAA . 246 7.3.2.2 Stand Alone JPH 248 7.3.3 Analysis of Buffer Status . 250 7.4 Variation Reduction . 252 7.4.1 Concept of Variation Reduction . 252 7.
45、4.2 Characteristics of Variation Reduction 254 7.4.3 Multivariable Correlation Analysis 256 7.4.4 Quality Concern on Parallel Lines . 258 7.4.4.1 Data Distribution of Parallel Lines . 258 7.4.4.2 Variation of Two Lines with Different Variances . 259 7.4.4.3 Variation of Two Lines with Different Mean
46、s 260 7.4.4.4 Discussion of Parallel Line Variation . 260 7.5 Exercises . 262 7.5.1 Review Questions . 262 7.5.2 Research Topics . 263 7.5.3 Analysis Problems . 263 7.6 References . 264 Index 267 About the Author 277 6673_Book.indb 11 12/27/16 9:58 AM6673_Book.indb 12 12/27/16 9:58 AMxiii Preface I.
47、1 Approach Manufacturing engineering is more a practice than a pure science. The intent of this book is to review and discuss the comprehensive and sophisticated knowledge and practice of automotive manufacturing. This book studies the proven technologies and processes of automotive manufacturing, a
48、s well as its new advances. Hence, this book is fundamentals focused and applications oriented. In automotive manufacturing, professionals are practicing with the knowledge of many subjects. This book covers most of the manufacturing areas. In addition, it may be considered 80% technical and 20% man
49、agerial in nature, which reflects my viewpoints on automotive manufacturing. I am passionate about automotive manufacturing engineering, an appealing and dynamic engineering field, and having always been excited about learning new stuff. I recognize a significant gap between academic research and industrial practice as I worked in academia for 17 years and then over 16 years in the automotive industry. My appreciation of automotive manufacturing engineering motivates me to put my efforts into filling the gap by providing interdisciplinary review and discussion on manufac- turing techno
