1. FCM PROCESS REVIEW(ASSEMBLY PART)

2. FRONT CROSS MEMBER ASSEMBLY
Torque rod for differential + Screw(Station16-S05)
POWER SYSTEM BOX+ 1 Screw+ Self Locking Nut Screw (Station16-S04)
STABALIZER BAR ASSEMBLY+ 4 Screws + Link+ Self locking nut (Station16-S03)
FRONT CROSS MEMBER(Station16-S02)
CONTROL ARM ASSEMBLY+ 2 Screws for horizontal & vertical bush
(Station16-S01)
BALL JOINT+ 3 RIVETS (Station16-S01)
CONTROL ARM (Station16-S01)
VERTICAL BUSH (Station16-S01)
HORIZONTAL BUSH (Station16-S01)

3. 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 dan.

4. 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

5. 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

6. BOM for FCM ASSEMBLY

7. Child Parts for FCM ASSEMBLY
Screw M12*1.25*95
Screw M8*35
Pin drivetrain front suspension
Rondelle 12*24
Screw M12*1.25*115
Washer 12*24
Self locking Nut M12*1.25
Screw M12*170
FCM ASSEMBLY
Torque rod for differential
Stabalizer Link
Stabalizer Bar 20mm
Control arm
Ball joint
Horizontal bush
Screw M8*1.25*82
POWER SYSTEM
Vertical Bush
Rivet

8. 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

9. REAR AXLE PROCESS REVIEW (ASSEMBLY PART)

10. Self locking nut M12*1.25+ Washer 12*24
REAR DRUM FREE RUN TEST
(STATION 17-S07)
REAR AXLE ASSEMBLY
(STATION 17- S06)
REAR AXLE SUB ASSY
(STATION 17-S05)
Special Screw
REAR DRUM SUB ASSY
(STATION 17-S04)
Self locking nut M12*1.25+ Washer 12*24
Disc screw
SPACING RING
BRAKE DRUM ASSY
WHEEL HUB
BRAKE HOOK
WASHER
NUT M22*1.5
RT BRACKET COMPLABS(STATION 17-S03)
BRAKE DRUM
REAR STUB AXLE ABS
VITE SPECIAL
HATCH ROB+ M12*1.25*135
(STATION 17-S02)
REAR SUB ASSY
(Station 17-S01)

11. Rear Axle Assembly Rear Axle Assembly
1.First rear axle sub assembly is taken and then hatch rob is pressed with a pressure of PSI and then right bracket compl abs is fitted to the bush with a M12*1.25*135 screw and self locking nut M12* Then rear drum assembly is done where the rear stub axle is taken and fitted to brake drum with a vite special screw of 36Nm and to this wheel hub, brake hook, spacing ring, washer is inserted and to this a hub nut is tightened with a 280Nm torque. 3.Then a wheel hub cap is pressed with a load of 1000 dan. 4. At last disc screw is fitted with a torque of 12Nm. 5. Then the rear drum assembly is taken and fitted to rear axle with special screw and then rear drum free run is tested in a testing machine and is checked that resistance to its running is less than 5Nm.
Hatch Rob Pressing System
Wheel Hub Cap Pressing System
Rear Axle Assembly
Free Rear Drum Rotation Test

12. BOM for Rear Axle Assembly

13. Child Parts For Rear Axle Assembly
Brake Drum
Spacing Ring
Disc screw
Rear Axle
Hatch Rob
Right bracket Compl Abs
Special Screw
Rear Stub Axle Abs
Washer 12*24
Wheel Hub
Self Locking Nut M12*1.25
Screw M12*1.25*135
Washer
Brake Hook
Vite Special
Hub Nut

14. 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

15. Front Corner Module Process Review (Assembly Part)

16. Front Corner Module Assy (Station 18-S08)
Hub lock nut(Station 18-S07)
Drive Shaft(Station 18-S07)
Special hex flange bolt(Station 18-S07)
Self Locking Nut (Station 18-S07)
Flex pipe for brake(Station 18-S07)
Shock absorber assembly(Station 19-S06)
Brake caliper(With Improved Pads) (Station 18-S06)
Nut ring(Station 19-S05)
Disc run out test(Station 18-S05)
Shock absorber bearing(Station 19-S04)
Brake disc(Station 18-S04)
Cover for front brake(Station 18-S04)
Screw TCE M6*16(Station 18-S04)
Disc screw(Station 18-S04)
Rondelle(Station 19-S03)
Wheel Hub(Station 18-S03)
Spring(Station 19-S02)
Knuckle Sub Assembly (Station 18-S02)
Shock absorber strut(Station 19-S01)
Ball Bearing(Station 18-S01)
Circlip (Station 18-S01)

17. Front Corner Module Assembly
First ball Bearing and circlip is pressed with a load of PSI to knuckle in knuckle bearing system.
Then hub is pressed at a load of PSI
Then dust cover is bolted to knuckle sub assembly by normal screw M6*16 with a torque of 3Nm.
Then disc is fitted to it with 3no. disc screws with a torque of 12 Nm.
Then disc run out test is carried and is checked that the maximum run out is not more than 80.
Then caliper fitment is done with a caliper bolt
Then after corner module is assembled, shock absorber assembly from station no 19 is taken in which following process is done.
1. The suspension strut and spring is taken and kept in the machine and from top washer, self locking nut and shock absorber is fitted with a torque of 70Nm.
8. Then the shock absorber assembly is taken and fitted to knuckle with two special hex flange bolt and rondelle is inserted with a self locking nut with a torque of 100Nm, also drive shaft is fitted to disc assembly with a hub lock nut with 275 Nm torque and 56 deg for petrol and for diesel 310Nm torque and an angle of 62 deg is given for the hub lock nut.
Knuckle Bearing Pressing M/C
Shock Absorber assembly M/C

18. BOM for Front Corner Module Assembly

19. Child Parts For Corner Module Assembly
Special Hex Flange Bolt
Spring
Drive Shaft
Screw TCE M6*16
Flex Pipe
Hub Nut
Shock Absorber Strut
Caliper
Cover For front Brake
Disc Screw
Corner Module Assembly
Disc Brake
Wheel Hub
Shock Absorber bearing
Ball Bearing
Circlip
Rondelle
Self Locking Nut
Caliper Bolt
Nut Ring

20. POKA YOKE
1. For fitment of drive shaft and shock absorber the holder for disc assembly is such that we can recheck that proper caliper fitment is done or no. 2.For disc run out test there are sensors to sense the job and if something is missing then machine wont start. 3. For bearing pressing there are sensors for bearing and circlip and if any one of them is missing then machine wont work. 4.In shock absorber fitting a sensor is provided in torque wrench which will sense presence of washer and if its not present then torque wont be given.
Circlip Sensor
Bearing Sensor
Job Sensors
Washer Sensor
Holder for checking proper calliper is fitted

21. THANK YOU