1. FCM PROCESS REVIEW(ASSEMBLY PART)

2. 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)

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

6. Child Parts for FCM Assy
Screw M8*35
Pin drivetrain front suspension
Rondelle 12*24
Screw M12*1.25*95
Screw M12*1.25*115
Washer 12*24
Screw M12*170
Self locking Nut M12*1.25
Stabalizer Link
Stabalizer Bar 20mm

7. 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 putting socket of the specified torque wrench in the machine so that proper torque is given and its also rechecked by the torque reader.

8. 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)
SPACING RING
BRAKE DRUM ASSY
WHEEL HUB
BRAKE HOOK
WASHER
NUT M22*1.5
REAR DRUM SUB ASSY
(Station 17-S01)
HATCH ROB
(STATION 17-S02)
RT BRACKET COMPL ABS(STATION 17-S03)
BRAKE DRUM
REAR STUB AXLE ABS
VITE SPECIAL