Metal Pressings
Thursday, August 13, 2009 at 12:38PM | Vehicle Design Summit Ever wondered how steel car panels are made? A couple of weeks ago we had the opportunity to find out! (I was pretty excited -- I am studying engineering after all!)
A group of us visited a local steel pressings plant. We were first welcomed by a long row of huge machines each about 30 feet tall, and the deafening noise of every one coming down with extreme force to blank, form, draw, pierce and trim steel, which they appeared to do with ease. Men loaded each machine with flat sheet metal, or a partially-made part, and, appearing like magic, a huge piece of the machine fell and rose, leaving an entirely different piece. The new parts were immediately removed from the machine, and the workers reloaded each in seconds. Man and machine worked like one, in fluid motion. Pieces moved down the row of machines, each making it's own mark until there were tall piles of completed stampings with beautiful finishes.
We asked about worker turnover, and were interested to learn that most of the factory employees only work there for about 6 months. The reason is that this is the length of their initial contract. Once their contracts come up for renewal, most workers expect a raise, which the company is hesitant to offer, unless their work is of the highest quality, because they know there are plenty of new people they can hire. (Another company, which I'll write about later, has a very different approach to hiring)
After pressings, the pieces -- car door panels, hoods, etc. -- moved to the welding area, which was again done by hand. Here in India, labor is easy to find and inexpensive, so it is used extensively in manufacturing. The factory had rack upon rack of completed car side panels, which are for cars by Indian, Italian, and U.S. car companies.
There was also a very neat robot that bent the hood sheet over a structural piece. With perfect automation, it ran over the edges of the seam multiple times, each at a different angle, until there was a perfect fold. The clamps holding the entire piece down also lifted in time for the robot arm to work under each, which led to a rippling wave effect.
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