How modern vehicles are manufactured

We continuously hear about the future of automotive: autonomous, connected, electric vehicles filled with technology, AI, and much more electronics than mechanics.

But what lies behind the manufacturing processes of the cars of the future?

Since Henry Ford popularized mass automobile production with 15 million Model T vehicles and the implementation of production lines, manufacturing processes have undergone significant changes.

We are moving towards a model where quality matters more than quantity, with new energy transition legislations as a backdrop.

Amidst this scenario, it is logical for industries to continuously seek innovative and technological solutions to improve manufacturing times, process quality, and, above all, design.

If you want to learn more about production lines in the automotive sector, join us in this post…😎

Manufacturing models in the automotive sector

The automotive sector is based on complex production lines and supply chains that involve high innovation and technology.

Components are manufactured in different production processes and finally assembled to create the finished vehicle.

Attention: Each phase of the manufacturing process influences costs and industry competitiveness.

The essence of the business is based on maximizing efficiency and strict quality controls to achieve results.

From this reality, we see that the predominant manufacturing models for vehicles are:

• Mass Production: Large quantities of vehicles are produced to minimize unit costs. This is the most traditional assembly line for mid- and low-range vehicles, optimizing costs and manufacturing times.
• Custom Manufacturing: Production models based on customer specifications, usually the norm for selling higher-end vehicles.
• Just In Time (JiT) Manufacturing: Components that make up the vehicles are produced and assembled just in time, avoiding excesses and shortages. This model was proposed by Toyota in 1938. It reduces risks and maintenance costs, allowing a low inventory level. This model is often complemented by the JIS (Just in Sequence) logistics supply model.
• Flexible Manufacturing: FMS production models rely on technologies and rapid adjustment processes to more easily adapt to changes in demand.

These manufacturing models are not incompatible and are often combined within the same industry to focus its production system.

What is evident is that the use of new technologies and control of production processes is crucial in any of them to obtain maximum competitive advantages in the industry.

How long does it take to manufacture a vehicle?

The manufacturing time of a vehicle can be viewed from different perspectives:

• The time it takes to assemble the parts
• The entire production process of each piece and component
• The period from when a customer places an order until the car arrives at the dealership

Assembly Time

‍If we talk about assembly per unit and mass-produced vehicles, without custom specifications, according to the car sales portal CarWow, the average time to assemble a car can currently be around 15 hours, whereas a few decades ago, it could take up to 60 hours.

The advanced and innovative technologies that the automotive industry is implementing allow the assembly period of a vehicle’s parts to be reduced to incredibly low levels. Such is the case of vehicles like the Tesla Model Y in China, whose production plant allows a vehicle to roll off the assembly line every 40 seconds.

Production Time

‍However, if we talk about the production time of all the parts of a vehicle, the figures can vary between 4 and 6 years, according to Volvo.

This shows the enormous complexity of supply chains and the importance of process planning and demand forecasting to deliver effective results.

Time from Order to Delivery

The delivery process of the assembled and finished vehicle can range from 4 to 6 months. It all depends on the specifications it has.

In this regard, it is essential to consider that the assembly of parts does not imply the total completion of the product, nor does it take into account the complexity of logistics and transportation processes.

How are vehicles manufactured today? The phases of the production process

Although car production processes can vary among different manufacturers, here’s how a typical production process in the automotive sector works.

It’s important to note that automation systems and industrial robotics play a significant role in the assembly line.

1. Design and Development

‍Plans are drawn up for the body, chassis, engine, transmission, and other components.

This is a crucial phase in the product creation process, where the investment in R&D of the automotive company is key to success.

New Mixed Reality technologies like Uktena can be incorporated for prototype design, providing professionals with the assistance they need at each phase to leverage the company's accumulated knowledge, adhere to quality standards, and comply with industry regulations.

2. Virtual Testing

‍Once the product design is developed, virtual tests are conducted using simulation software solutions to check aerodynamics, safety, and design.

This stage allows for risk optimization, detecting faults, and identifying needs to improve the product design before it goes into production.

3. Material Acquisition

‍The supply chain is an essential part of car manufacturing. The most suitable materials for each piece must be selected to achieve the best performance and durability.

Additionally, controlling the supply chain requires considering the manufacturing times and costs of the components that will make the finished vehicle possible.

4. Press Stamping

‍Using a robust and powerful press, each piece that will be part of the vehicle is manufactured from metal sheets.

Dies or molds are developed to shape the metal sheet. The press exerts pressure on the sheet, forcing it through the die until it takes the desired shape.

Here, it is also crucial to control metal cutting operations and minimize leftover material.

5. Quality Control

‍Quality control is a vital part before the assembly process begins. It is essential to verify the quality of each piece to ensure it matches the design.

Factors such as dimensions, shape, appearance, and resistance to various variables are measured.

6. Cutting and Welding

‍During this phase, excess metal is removed, each element is cleaned, and the edges of the pieces are fused.

The spot welding method is used, applying an electric current through electrodes to join the pieces, generating heat to melt the metal and unite the pieces.

Another method used is arc welding, where an electrode produces an electric arc between the metal pieces. Here, the metal is melted at the points of union, and filler material can be used to reinforce the joint.

7. Painting

‍This is a highly relevant stage, aiming to ensure the vehicle's appearance and guarantee its protection against corrosion and durability.

During this phase, a first coat (called “primer”) is applied to facilitate the adhesion of automotive paint through priming. The next step involves applying the base coat, which defines the car’s final color.

Lastly, a clear coat or finish is applied, giving the vehicle’s paint the gloss and weather and UV resistance it needs.

8. Drying and Curing

‍Once the vehicle’s paint is completed, two essential processes are carried out:

• ‍Drying: The vehicle paint transitions from liquid to solid, solvents start to evaporate, leaving solid pigments.
• ‍Curing: This process allows the automotive paint to harden.

9. Chassis assembly and suspension Installation

‍Next, shock absorbers and elements necessary for driving safety and vehicle handling are installed.

Then, the steering and brakes are assembled, disks and calipers are mounted on the chassis, and the engine and transmission are installed.

During this part of the process, the exhaust system is also installed and connected to the engine. Finally, the electrical and fuel systems are installed.

10. Testing and Adjustments

‍Testing and adjustments are crucial to ensure the vehicle's proper functioning.

Functional tests are carried out for the engine, transmission, steering, and brakes to make any adjustments necessary to ensure the vehicle meets quality and safety standards.

11. Body Assembly

‍The next step is body assembly, which involves installing the roof, windows, and all exterior components, including the car’s lighting system.

12. Quality Testing

‍At this stage of the assembly line, various quality, safety, and optimal functioning tests are conducted to verify that the entire vehicle and each of its components meet brand standards and legal requirements.

13. Packaging and Shipping

‍Finally, the vehicle leaves the production line, is prepared, and shipped through a careful logistics process to ensure the final product arrives in perfect condition at the dealership where the vehicle was ordered, or for distribution.

New technologies transforming the automotive industry

Discussing the automotive sector involves considering that AI, Big Data, Robotics, the Internet of Things, or Virtual and Augmented Reality play roles in design, production, logistics, and sales processes.

Industry 4.0 has had a significant impact on the automotive sector, transforming its processes to reduce manufacturing times and facilitate logistics and warehouse operations.

The integration of AI has revolutionized quality control in automotive manufacturing by analyzing real-time data, identifying patterns and anomalies in the production process. This allows early detection of potential defects, significantly improving the final product's quality and reducing costs associated with manufacturing errors.

Additionally, AI has proven invaluable for training and educating personnel in car factories. Through AI systems, detailed and personalized instructions can be provided on how to perform specific production processes without intensive training. This accelerates the learning curve of employees, increases operational efficiency, and reduces costs associated with traditional training.

If you want to know how Uktena could help your industry in this area, we invite you to chat with us.