FCM PROCESS REVIEW(ASSEMBLY PART)

FRONT CROSS MEMBER ASSEMBLY CONTROL ARM ASSEMBLY (MESA-Station16) FRONT CROSS MEMBER(MESA-Station 16) POWER SYSTEM BOX(MESA-Station 16) STABALIZER BAR ASSEMBLY(MESA-Station 16) BALL JOINT+ 3 RIVETS (MESA-Station16) CONTROL ARM (MESA-Station16) VERTICAL BUSH (MESA-Station16) HORIZONTAL BUSH (MESA-Station16)

Process Study FCM Area :-Station 16 Swing Arm bush Pressing Steps-: Place the Swing arm on the bush pressing machine. Apply soap solution and see to it that the vertical bush is 30deg angle and then apply load of 300- 1000 dan.

POKA YOKE 1.Locting Pin for vertical bush is given so that 30 deg angle is maintained. 2. Material Sensor is provided which will sense the presence of material. 3. Hand sensors are present to sense any presence of body parts during working of machine. Material Sensor Locating Pin for vertical bush

FCM Assembly(MESA-Station 16) The assembled control arm is taken and it is fitted to FCM by 2 screw M12*1.25*95 and two self locking nut M12*1.25 vertically and 2 screw M12*1.25*115 horizontally with a torque of 135 Nm Power system from trolley is taken and fitted to FCM with two screws M12*170 and two Rondelle 12*24 by a torque of 88 Nm The stabilizer bar is fitted with 4 special screw M8*35 with a 24 Nm and the to the bar 2 link is fitted with 1 self locking nut M12*1.25 each link. The torque rod for differential is fitted to FCM with a Screw M8*1.25*82 FCM ASSEMBLY

Child Parts for FCM ASSEMBLY Rondelle 12*24 Screw M8*35 Pin drivetrain front suspension Screw M12*1.25*95 Screw M12*1.25*115 Washer 12*24 Screw M12*170 Self locking Nut M12*1.25 FCM ASSEMBLY Torque rod for differential Stabalizer Link Stabalizer Bar 20mm POWER SYSTEM

POKA YOKE Holding fixture is provided for fitment of FCM Torque reader is also provided which is used by worker to cross check the applied torque. Every torque wrench is error proofed by removing socket of the specified torque wrench in the machine so that proper torque is given and its also rechecked by the torque reader. Holding fixture where fcm is assembled M/c to give specified torque by removing the particular socket Socket

Rear Axle Process Review(Assembly ) REAR DRUM FREE RUN TEST (STATION 17-S07) REAR AXLE ASSEMBLY (STATION 17- S06) REAR AXLE SUB ASSY (STATION 17-S05) REAR DRUM SUB ASSY (STATION 17-S04) REAR SUB ASSY (Station 17-S01) HATCH ROB (STATION 17-S02) RT BRACKET COMPL ABS(STATION 17-S03) SPACING RING BRAKE DRUM ASSY WHEEL HUB BRAKE HOOK WASHER NUT M22*1.5 BRAKE DRUM REAR STUB AXLE ABS VITE SPECIAL

POKA YOKE For Rear Drum assy following are the poka yoke:- For hub nut tightening a sensor is provided which will sense that a proper torque is given or no and if its not given then the job doesn’t gets declamped. Hand sensors are provided in wheel hub cap pressing m/c to sense presence of any body part during working of m/c for safety. Tool holder are provided when the rear drum assembly is fitted to the rear axle by torque wrench. Tool holder Hand sensors Sensor to sense proper torque is given to the hub nut

Front Corner Module Front Corner Module Assy Hub lock nut Drive Shaft Disc assembly Special hex flange bolt Flex pipe for brake Shock Absorber Assembly Knuckle Sub Assembly Brake disc Brake caliper(With Improved Pads) Cover for front brake Wheel Hub Screw TCE M6*16 Disc screw Rondelle Ball Bearing Circlip

POKA YOKE