Car Manufacturing Process

Initial Stages

• Material Preparation: Despite the cost of the car, it starts as a coil of aluminum.
• Pressing: A 5,000-ton press forms the aluminum into car parts such as the hood, trunk, body, and small parts like mirrors and doors.

Assembly of Car Body

• Parts Assembly:
  • Car body comprises about 500 parts.
  • Joined with approximately 2,000 welds.
• Conveyor System: Moves the assembled body to the painting stage.

Painting

• Priming: Ensures surface smoothness, corrosion protection, and paint adhesion.
• Painting:
  • Five coats applied using robotic hands with sprays.
  • Uses about 100 pounds of paint per car.
• Electric Charge Painting: Ensures even thickness of paint, especially on car doors.
• Polishing: Under bright lights to identify scratches, polished to a shine.

Interior Preparation

• Leather Cutting:
  • Inspected for imperfections.
  • Laser projection for efficient cutting.
• Seat Assembly:
  • Leather pieces sewn and stuffed with foam.
  • Air-tight bag technique used for fitting.

Engine and Transmission Installation

• Engine Installation:
  • Engine lifted and mounted under the hood.
  • Vibration-absorbing mounts used.
• Engine Functioning: Involves fuel-air mixture ignition causing cylinder movement.
• Transmission (Gearbox) Installation:
  • Contains rotating shafts with gears.
  • Connected to the engine through a clutch.
• Drive System:
  • Rear-wheel drive connected through a drive shaft and differential.

Additional Installations

• Suspension and Brakes:
  • Includes steering beams, shock absorbers, brake discs.
• Exhaust System:
  • Reduces noise with a muffler.
  • Chrome exhaust pipe for gas expulsion.

Final Stages

• Air and Fuel Systems:
  • Air filter cleans air before entering engine.
  • Fuel filter ensures clean fuel.
• Electrical Systems:
  • Battery and generator manage electrical energy.
  • Electrical relay distributes power via extensive wiring.

Interior and Exterior Finalization

• Interior Assembly:
  • Front panel, seats, steering wheel, airbags installed.
  • Electronics connected.
• Exterior Parts: Windshields, doors, decorative elements added.

Testing

• Quality Inspection: Under bright lights for defects.
• Water Tightness Test: Simulates heavy rain.
• Dynamo Test: Checks acceleration and braking.

Conclusion

• Once tests are successful, cars are shipped to dealerships for sale.